FG-100 User Manual Firmware V-5.

FG-100
ADVANCED
GENSET
CONTROLLER

DESCRIPTION COMMUNICATIONS
The FG-100 series are next generation genset • USB Device
control units combining multi-functionality and wide • J1939-CANBUS (optional)
communication possibilities together with a reliable • RS-485 Modbus (optional)
and low cost design. • GSM Modem 2G or 3G (optional)
The unit complies and mostly exceeds world’s • Ethernet 10/100 Mb (optional)
tightest safety, EMC, vibration and environmental • Free PC software: Rainbow Plus
standards for the industrial category. • Modbus RTU through USB
• Ready Rainbow Scada central monitoring
Software features are complete with easy firmware
service
upgrade process through USB port.
The Windows based PC software allows monitoring
and programming through USB, serial and GPRS.
The PC based Rainbow Scada software allows
monitoring and control of an unlimited number of TOPOLOGIES
gensets from a single central location.
3 phases 4 wires, star
3 phases 3 wires, 3 CTs, delta
FUNCTIONALITIES 3 phases 3 wires, 2 CTs (L1-L2)
3 phases 3 wires, 2 CTs (L1-L3)
Remote start controller 2 phases 3 wires, L1-L2
Manual start controller 3 phases 4 wires, delta
Engine controller 1 phase 2 wires
FG-100 User Manual Firmware V-5.8

COPYRIGHT NOTICE

Any unauthorized use or copying of the contents or any part of this document is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

ABOUT THIS DOCUMENT

This document describes minimum requirements and necessary steps for the successful installation of
the FG-100 family units.
Follow carefully advices given in the document. These are often good practices for the installation of
genset control units which reduce future issues.

QUERRIES
If additional information to this manual is required, please contact FG Wilson technical helpdesk

Please provide following information in order to get answers to any question:

- Device model name (see the back panel of the unit),

- Complete serial number (see the back panel of the unit),
- Firmware version (read from the display screen),
- Measuring-circuit voltage and power supply voltage,
- Precise description of the query.

RELATED DOCUMENTS

FILENAME DESCRIPTION
Rainbow Installation Rainbow Plus Installation Guide
Rainbow Usage Rainbow Plus Usage Guide
GSM Configuration GSM Configuration Guide
Firmware Update Firmware Update Guide for FG-100
MODBUS Modbus Application Manual
Rainbow Scada Installation Rainbow Scada Installation Guide
Rainbow Scada Usage Rainbow Scada Usage Guide

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FG-100 User Manual Firmware V-5.8

REVISION HISTORY

REVISION DATE AUTHOR DESCRIPTION

01 15.12.2017 MH First edition, firmware version 5.8
02 28.05.2018 MH -Emergency Stop input modified to be positive and moved to
Input_6.
-Oil Pressure Sender input modified for 0-5V analog.
-Chapters 3.4 and 3.5 rewritten.

TERMINOLOGY

CAUTION: Potential risk of injury or death.

WARNING: Potential risk of malfunction or material damage.

ATTENTION: Useful hints for the understanding of device operation.

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 FG-100 User Manual Firmware V-5.8

ORDERING CODES

The FG-xxx family units are available in various options and peripheral features. Please use below
information for ordering the correct version:

FG100 -J -G -T -00

Variant
00: standard unit
Family Code 01...99: customer
specific products

With CANBUS- With Sealing With Conformal

J1939 port gasket Coating

SPARE PARTS

Screw type bracket Self Retaining type bracket

Stock Code=J10P01 (per unit) Stock Code=K16P01 (per unit)

Sealing Gasket

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FG-100 User Manual Firmware V-5.8

SAFETY NOTICE
Failure to follow below instructions
will result in death or serious injury

 Electrical equipment should be installed only by qualified

specialist. No responsibility is assured by the manufacturer or
any of its subsidiaries for any consequences resulting from the
non-compliance to these instructions.
 Check the unit for cracks and damages due to transportation. Do
not install damaged equipment.

 Do not open the unit. There are no serviceable parts inside.

 Fuses must be connected to the power supply and phase voltage

inputs, in close proximity of the unit.
 Fuses must be of fast type with a maximum rating of 6A.

 Disconnect all power before working on equipment.

 When the unit is connected to the network do not touch

terminals.

 Short circuit terminals of unused current transformers.

 Any electrical parameter applied to the device must be in the

range specified in the user manual. Although the unit is designed
with a wide safety margin, over-range parameters may reduce
lifetime, alter operational precision or even damage the unit.
 Do not try to clean the device with solvent or the like. Only clean
with a dump cloth.

 Verify correct terminal connections before applying power.

 Only for front panel mounting.

Current Transformers must be used for current measurement.

No direct connection allowed.

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FG-100 User Manual Firmware V-5.8

TABLE OF CONTENTS

1. INSTALLATION INSTRUCTIONS
2. MOUNTING
2.1 DIMENSIONS
2.2 SEALING, GASKET
2.3 ELECTRICAL INSTALLATION
3. TERMINAL DESCRIPTIONS
3.1. BATTERY VOLTAGE INPUT
3.2. AC VOLTAGE INPUTS
3.3. AC CURRENT INPUTS
3.4. DIGITAL INPUTS
3.5. ANALOG SENDER INPUTS, SENDER GROUND AND SENDER SUPPLY
3.6. CHARGE INPUT TERMINAL
3.7. DIGITAL OUTPUTS
3.8. J1939-CANBUS PORT (OPTIONAL)
3.9. USB DEVICE PORT
3.10. GSM MODEM (OPTIONAL)
3.11. RS-485 PORT (OPTIONAL)
3.12. ETHERNET PORT (OPTIONAL)
4. TOPOLOGIES
4.1. SELECTING THE TOPOLOGY
4.2. 3 PHASE, 4 WIRE, STAR
4.3. 3 PHASE, 3 WIRE, DELTA
4.4. 3 PHASE, 4 WIRE, DELTA
4.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)
4.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)
4.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)
4.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)
4.9. 1 PHASE, 2 WIRE
5. FUNCTIONALITIES
5.1. REMOTE START FUNCTIONALITY
5.2 ENGINE CONTROLLER FUNCTIONALITY
6. CONNECTION DIAGRAMS
6.1. REMOTE START FUNCTIONALITY
6.2. ENGINE CONTROL FUNCTIONALITY

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FG-100 User Manual Firmware V-5.8

7. TERMINAL DESCRIPTION
8. TECHNICAL SPECIFICATIONS
9. DESCRIPTION OF CONTROLS
9.1. FRONT PANEL FUNCTIONALITY
9.2. PUSHBUTTON FUNCTIONS
9.3. DISPLAY SCREEN ORGANIZATION
9.4. MEASURED PARAMETERS
9.5. LED LAMPS
10. DISPLAYING EVENT LOGS
11. STATISTICAL COUNTERS
11.1. FUEL CONSUMPTION MONITORING
12. OPERATION OF THE UNIT
13.1. QUICK START GUIDE
13.2. STOP MODE
13.3. AUTO MODE
13.4. RUN MODE, MANUAL CONTROL
13.5. TEST MODE
13. PROTECTIONS AND ALARMS
13.1. DISABLING ALL PROTECTIONS
13.2. SERVICE REQUEST ALARM
13.3. LIST OF ALARMS
13.4. NON-VISUAL WARNINGS
14. PROGRAMMING
14.1. RESETTING TO FACTORY DEFAULTS
14.2. ENTERING THE PROGRAMMING MODE
14.3. NAVIGATING BETWEEN MENUS
14.4. MODIFYING PARAMETER VALUE
14.5. PROGRAMMING MODE EXIT
15. PROGRAM PARAMETER LIST
16. CRANK CUTTING
17. OVERCURRENT PROTECTION (IDMT)
18. MOTORIZED CIRCUIT BREAKER CONTROL
19. J1939 CANBUS ENGINE SUPPORT
20. SMS COMMANDS

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FG-100 User Manual Firmware V-5.8

21. SOFTWARE FEATURES

21.1. LOAD SHEDDING / DUMMY LOAD
21.2. LOAD ADD / SUBTRACT
21.3. FIVE STEP LOAD MANAGEMENT
21.4. REMOTE START OPERATION
21.5. DISABLE AUTO START, SIMULATE MAINS
21.6. BATTERY CHARGING OPERATION, DELAYED SIMULATE MAINS
21.7. DUAL GENSET MUTUAL STANDBY OPERATION
21.8. MULTIPLE VOLTAGE AND FREQUENCY
21.9. SINGLE PHASE OPERATION
21.10. EXTERNAL CONTROL OF THE UNIT
21.11. ENGINE HEATING OPERATION
21.12. ENGİNE IDLE SPEED OPERATİON
21.13. ENGINE BLOCK HEATER
21.14. FUEL PUMP CONTROL
21.15. GAS ENGINE FUEL SOLENOID CONTROL
21.16. PRE-TRANSFER SIGNAL
21.17. CHARGING THE ENGINE BATTERY
21.18. EXTERNALLY CONTROLLED DIGITAL OUTPUTS
21.19. COMBAT MODE
21.20. RESETTING THE CONTROLLER
21.21. ZERO POWER AT REST
22. DECLARATION OF CONFORMITY
23. MAINTENANCE
24. DISPOSAL OF THE UNIT
25. ROHS COMPLIANCE
26. TROUBLESHOOTING GUIDE

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FG-100 User Manual Firmware V-5.8

1. INSTALLATION INSTRUCTIONS

Before installation:
 Read the user manual carefully, determine the correct connection diagram.
 Remove all connectors and mounting brackets from the unit, then pass the unit through the
mounting opening.
 Put mounting brackets and tighten. Do not tighten too much, this can brake the enclosure.
 Make electrical connections with plugs removed from sockets, then place plugs to their sockets.
 Be sure that adequate cooling is provided.
 Be sure that the temperature of the environment will not exceed the maximum operating
temperature in any case.

Below conditions may damage the device:

 Incorrect connections.
 Incorrect power supply voltage.
 Voltage at measuring terminals beyond specified range.
 Voltage applied to digital inputs over specified range.
 Current at measuring terminals beyond specified range.
 Overload or short circuit at relay outputs
 Connecting or removing data terminals when the unit is powered-up.
 High voltage applied to communication ports.
 Ground potential differences at non-isolated communication ports.
 Excessive vibration, direct installation on vibrating parts.

Current Transformers must be used for current

measurement.
No direct connection allowed.

Below conditions may cause abnormal operation:

 Power supply voltage below minimum acceptable level.
 Power supply frequency out of specified limits
 Phase order of voltage inputs not correct.
 Current transformers not matching related phases.
 Current transformer polarity incorrect.
 Missing grounding.

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FG-100 User Manual Firmware V-5.8

2. MOUNTING

2.1. DIMENSIONS

Dimensions: 133x107x46mm (5.25”x4.2”x1.9”)

Panel Cutout: 117x87mm minimum (4.6”x3.43”)
Weight: 200g (0.45 lb)

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FG-100 User Manual Firmware V-5.8

The unit is designed for panel mounting. The user

should not be able to access parts of the unit other
than the front panel.

Mount the unit on a flat, vertical surface. Before mounting, remove the mounting brackets and connectors
from the unit, then pass the unit through the mounting opening.

Place and tighten mounting brackets.

87mm

117mm

Panel Cutout

WALL

min 60mm 40mm

Required Panel Depth

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FG-100 User Manual Firmware V-5.8

Two different types of brackets are provided:

Screw type bracket Self retaining type bracket

Installation of screw type bracket Installation of self retaining type bracket

Do not tighten too much, this may break the unit.

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FG-100 User Manual Firmware V-5.8

2.2. SEALING, GASKET

Panel

Gasket

Module

The rubber gasket provides a watertight means of mounting the module to the genset panel. Together
with the gasket, IEC 60529-IP65 protection can be reached from the front panel. A short definition of IP
protection levels is given below.

1st Digit Description of Protection Level

0 Not protected
1 Protected against solid foreign objects of 50 mm diameter and greater
2 Protected against solid foreign objects of 12,5 mm diameter and greater
3 Protected against solid foreign objects of 2,5 mm diameter and greater
4 Protected against solid foreign objects of 1,0 mm diameter and greater
5 Protected from the amount of dust that would interfere with normal operation
6 Dust tight

2nd Digit Description of Protection Level

0 Not protected
1 Protected against vertically falling water drops
2 Protected against vertically falling water drops when enclosure is tilted up to 15 °
3 Protected against water sprayed at an angle up to 60 ° on either side of the vertical
4 Protected against water splashed against the component from any direction
5 Protected against water projected in jets from any direction
6 Protected against water projected in powerful jets from any direction
7 Protected against temporary immersion in water
8 Protected against continuous immersion in water, or as specified by the user

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FG-100 User Manual Firmware V-5.8

2.3. ELECTRICAL INSTALLATION

Do not install the unit close to high electromagnetic

noise emitting devices like contactors, high current
busbars, switchmode power supplies and the like.

Although the unit is protected against electromagnetic disturbance, excessive

disturbance can affect the operation, measurement precision and data communication
quality.
 ALWAYS remove plug connectors when inserting wires with a screwdriver.

 Fuses must be connected to the power supply and phase voltage inputs, in
close proximity of the unit.

 Fuses must be of fast type with a maximum rating of 6A.

 Use cables of appropriate temperature range.

 Use adequate cable section, at least 0.75mm2 (AWG18).

 Follow national rules for electrical installation.

 Current transformers must have 1A or 5A output.

 For current transformer inputs, use at least 1.5mm2 section (AWG15) cable.

 The current transformer cable length should not exceed 1.5 meters. If
longer cable is used, increase the cable section proportionally.

Current Transformers must be used for current

measurement.
No direct connection allowed.

The engine body must be grounded. Otherwise faulty

voltage and frequency measurements may occur.

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FG-100 User Manual Firmware V-5.8

3. TERMINAL DESCRIPTIONS

3.1. BATTERY VOLTAGE INPUT

Supply voltage: 8 to 36VDC

Cranking dropouts: Survives 0VDC during 100ms. The voltage before surge should be
8VDC minimum
Overvoltage protection: Withstands 150VDC continuously.
Reverse voltage: -33VDC continuous
Maximum operating 200mA @ 12VDC. (All options included, digital outputs open.)
current: 100mA @ 24VDC. (All options included, digital outputs open.)
Typical operating current: 100mA @ 12VDC. (all options passive, digital outputs open)
50mA @ 24VDC. (all options passive, digital outputs open)
Measurement range: 0 to 36VDC
Display resolution: 0.1VDC
Accuracy: 0.5% + 1 digit @ 24VDC

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FG-100 User Manual Firmware V-5.8

3.2. AC VOLTAGE INPUTS

Measurement method: True RMS

Sampling rate: 4096 Hz
Input voltage range: 14 to 300 VAC
Minimum voltage for 15 VAC (Ph-N)
frequency detection:
Supported topologies: 3 ph 4 wires star
3 ph 3 wires delta
3ph 4 wires delta
2ph 3 wires L1-L2
2ph 3 wires L1-L3
1 ph 2 wires
Measurement range: 0 to 330VAC ph-N (0 to 570VAC ph-ph)
Common mode offset: max 100V between neutral and BAT-
Input impedance: 4.5M-ohms
Display resolution: 1VDC
Accuracy: 0.5% + 1 digit @ 230VAC ph-N (±2VAC ph-N)
0.5% + 1 digit @ 400VAC ph-ph (±3VAC ph-ph)

Frequency range: DC to 100Hz

Frequency display 0.1 Hz
resolution:
Frequency accuracy: 0.2% + 1 digit (±0.1 Hz @ 50Hz)

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FG-100 User Manual Firmware V-5.8

3.3. AC CURRENT INPUTS

Measurement method: True RMS

Sampling rate: 4096 Hz
Supported topologies: 3 ph 3 CTs
3 ph 2 CTs L1-L2
3 ph 2 CTs L1-L3
2 ph 2 CTs L1-L2
2 ph 2 CTs L1-L3
1 ph 1 CT
CT secondary rating: 1A or 5A
Measurement range: 5/5 to 5000/5A minimum
Input impedance: 15 mili-ohms
Burden: 0.375W
Maximum continuous 6A
current:
Measurement range: 0.1 to 7.5A
Common mode offset: Max 5VAC between BAT- and any CT terminal.
Display resolution: 1A
Accuracy: 0.5% + 1 digit @ 5A (± 4.5A @ 5/500A full range)

SELECTING THE CT RATING AND CABLE SECTION:

The load on a CT should be kept

minimum in order to minimize phase shift
effect of the current transformer. Phase
shift in a CT will cause erroneous power
and power factor readings, although amp
readings are correct.
We advise CT rating to be selected
following this table for the best
measurement accuracy.

SELECTING THE CT ACCURACY CLASS:

The CT accuracy class should be selected in accordance with the required measurement precision. The
accuracy class of the FG100 controller is 0.5%. Thus 0.5% class CTs are advised for the best result.

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FG-100 User Manual Firmware V-5.8

 Current transformers must be used for current

measurement. No direct connection allowed.
 No common terminals or grounding allowed.

CONNECTING CTs:
Be sure of connecting each CT to the related phase input with the correct polarity. Mixing CTs between
phases will cause faulty power and pf readings.
Many combinations of incorrect CTs connections are possible, so check both order of CTs and their
polarity. Reactive power measurement is affected by incorrect CTs connection in similar way as active
power measurement.

CORRECT CT CONNECTIONS

Let’s suppose that the genset is loaded with 100 kW on each phase. The load Power Factor (PF) is 1.
Measured values are as follows:

kW kVAr kVA pf
Phase L1 100.0 0.0 100 1.00
Phase L2 100.0 0.0 100 1.00
Phase L3 100.0 0.0 100 1.00
Total 300.0 0.0 300 1.00

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FG-100 User Manual Firmware V-5.8

EFFECT OF POLARITY REVERSAL

The generator is still loaded with 100 kW On each phase. The load Power Factor (PF) is 1.
PF in phase L2 will show -1,00 due to reverse CT polarity. The result is that total generator power
displayed by the controller is 100 kW.
Measured values are as follows:

kW kVAr kVA pf
Phase L1 100.0 0.0 100 1.00
Phase L2 -100.0 0.0 100 -1.00
Phase L3 100.0 0.0 100 1.00
Total 100.0 0.0 300 0.33

EFFECT OF PHASE SWAPPING

The generator is still loaded with 100 kW on each phase. The load Power Factor (PF) is 1.
PF in phases L2 and L3 will show -0,50 due to phase shift between voltages and currents which is
caused by CT swapping. The result is that total generator power displayed by controller is 0 kW.
Measured values are as follows:

kW kVAr kVA pf
Phase L1 100.0 0.0 100 1.00
Phase L2 -50.0 86.6 100 -0.50
Phase L3 -50.0 -86.6 100 -0.50
Total 0.0 0.0 300 0.0

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FG-100 User Manual Firmware V-5.8

3.4. DIGITAL INPUTS

Type of inputs: Inputs 1-5: active negative

Input_6: active positive
Function selection: from list
Contact type: Normally open
Switching: Inputs 1-5: Battery negative
Input_6: battery positive
Structure: Inputs 1-5: 47 k-ohms resistor to battery positive
Input_6: 147 k-ohms resistor to battery negative
Open circuit voltage: Inputs 1-5: 75% of battery positive
Input_6: battery negative
Low level threshold: Inputs 1-5: 1.65VDC
High level threshold: Input_6: 5.20VDC
Maximum input voltage: +100VDC with respect to battery negative
Minimum input voltage: -70VDC with respect to battery negative
Noise filtering: Yes, both hardware and software.

3.5. ANALOG SENDER INPUTS, SENDER GROUND AND

SENDER SUPPLY

Type of inputs: all configurable, additional sender ground input and sender supply
output (+5VDC)
Function selection: from list
Sender supply: 5.0VDC, 20mA max.
Structure: Sender_1: analog voltage input (0-5V)
Senders_2-3: 667 ohms resistor polarizing to 3.3VDC
Measurement: Sender_1: analog voltage measurement
Senders_2-3: Analog resistor measurement.
Open circuit voltage: Sender_1: 0VDC
Senders_2-3: +3.3VDC
Short circuit current: 5mA (senders 2-3)
Measurement range: 0 to 5000 ohms. (senders 2-3)
Open circuit threshold: 5000 ohms. (senders 2-3)
Resolution: 1 ohms @ 300 ohms or lower (senders 2-3)
Accuracy: 2 %+1 ohm (±7 ohms @300 ohms) (senders 2-3)
Common mode voltage ± 3VDC (senders 2-3)
range:
Noise filtering: yes

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FG-100 User Manual Firmware V-5.8

The sender ground signal should be connected to the engine body, close to senders for the best
measurement accuracy. It can be left open if preferred.
The +5V supply output provides a maximum of 50mA for active sender types. It is protected by an internal
electronic fuse and resets automatically after an overload or short circuit condition.

3.6. CHARGE INPUT TERMINAL

The Charge terminal is both an input and output.
When the engine is ready to run, this terminal supplies the excitation current to the charge alternator.
The excitation circuit is equivalent to a 2W lamp.
The threshold voltages for warning and shutdown alarm are adjustable through program parameter.

Structure:  battery voltage output through 82 ohm resistor

 voltage measurement input
Output current: >100mA @12VDC
>200mA @24VDC
Voltage measurement 0.1VDC
resolution:
Voltage measurement 2% + 0.1V (0.9V @30VDC)
accuracy:
Charge Fail Warning adjustable
Threshold:
Charge Fail Shutdown adjustable
Alarm Threshold:
Open circuit voltage: battery positive
Overvoltage protection: > 500VDC continuous, with respect to battery negative
Reverse voltage -30VDC with respect to battery negative
protection:

3.7. DIGITAL OUTPUTS

Structure: Negative pulling protected semiconductor output. One terminal is

connected to battery negative.
Function programmable function, selectable from list.
Max continuous current: 1.0 ADC
Max switching voltage: 33 VDC
Overvoltage protection: 40 VDC
Short circuit protection: > 1.7 ADC
Reverse voltage 500 VDC
protection:

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FG-100 User Manual Firmware V-5.8

3.8. J1939-CANBUS PORT (OPTIONAL)

Structure: CANBUS, non isolated.

Connection: 3 wires (CANH-CANL-GND).
Data rate: 250 kbps
Termination: Internal 120 ohms provided
Common mode voltage: -0.5 VDC to +15 VDC, internally clamped by transient suppressors.
Max distance: 200m with 120 ohm balanced cable

The J1939 CANBUS port is optional. The same

terminals are shared with the MPU input.

3.9. USB DEVICE PORT

USB Device
Connector

USB A to B
Cable

Description: USB 2.0, not isolated, HID mode

Data rate: Full Speed 1.5/12 Mbits/s, auto detecting
Connector: USB-B (printer connector)
Cable length: Max 6m
Functionality: Modbus, FAT32 for firmware upgrade (boot loader mode only)

The USB-Device port is designed to connect the module to a PC. Using the RainbowPlus software,
programming, control of the genset and monitoring of measured parameters are achieved.
The RainbowPlus software can be downloaded from PowerUp 2 website.
The connector on the module is of USB-B type. Thus A to B type USB cable should be used. This is the
same cable used for USB printers.
For more details about programming, control and monitoring please refer to RainbowPlus user manual.

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FG-100 User Manual Firmware V-5.8

3.10. GSM MODEM (OPTIONAL)

The optional plug-in GSM modem offers the advantage of being internally powered and is fully compatible
with the unit. It does not require any special setup.
2G and 4G modem options are available.
The 1800/1900 MHz magnetic antenna together with its 2 meter cable is supplied with the modem. The
antenna is intended to be placed outside of the genset panel for the best signal reception.
The module requires a GPRS enabled SIM card for full functionality. Voice-only type SIM cards will
usually not function properly.
Please refer to GSM Modem Configuration Guide for more details.

SIM Card slot

Antenna connector

Magnetic antenna

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FG-100 User Manual Firmware V-5.8

WARNING: Different 4G modem versions are

necessary for North America and EMEA zones.

Description 2G modem: Quad-band GSM/GPRS 850/900/1800/1900MHz module.

GPRS multi-slot class 12/12
GPRS mobile station class B
Compliant to GSM phase 2/2+.
– Class 4 (2 W @850/ 900 MHz)
– Class 1 (1 W @ 1800/1900MHz)

Description 3G modem Four bands EGSM900, DCS1800, WCDMA-B1, WCDMA-B8

Compliant to GSM phase 2/2+.
– Class 4 (2 W @850/ 900 MHz)
– Class 1 (1 W @ 1800/1900MHz)
– Class 3 (0.25 W @ WCDMA)
Description 4G modem: Five-Band FDD-LTE B1/B3/B7/B8/B20
Dual-Band TDD-LTE B38/B40
Dual-Band UMTS/HSDPA/HSPA+ B1/B8
Dual-Band GSM/GPRS/EDGE 900/1800 MHz
Functionality: Web Client, SMTP, Modbus TCP/IP (client), SMS, e-mail
Operating temp range: -40°C to +85 °C
Data speed: max. 85.6 kbps (download), 85.6 kbps (upload)
SIM card type: external SIM 3V/1.8V, GPRS enabled
Antenna: Quad band, magnetic, with 2m cable
Module certificates: CE, FCC, ROHS, GCF, REACH

LOCATION DETERMINATION VIA GSM

The unit determines automatically the geographical position through the GSM network. No settings are
necessary for this.
This feature is especially useful for the remote monitoring where the controller will appear automatically at
its geo-position or for mobile gensets.
Although the controller supports also GPS location determination for more precise positioning, the GSM
based location is free of charge, available everywhere, even where GPS signal is not available.

The location precision will depend of the GSM

system. In highly populated areas, the precision is
good (a few hundred meters), but rural areas may
lead to errors of a many kilometers.

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FG-100 User Manual Firmware V-5.8

3.11. RS-485 PORT (OPTIONAL)

Structure: RS-485, isolated.

Connection: 3 wires (A-B-GND). Half duplex.
Baud rate: 2400-38400 bauds, selectable
Data type: 8 bit data, no parity, 1 bit stop
Termination: External 120 ohms required
Isolation: 250VAC, 1 minute
Common mode voltage: -0.5 VDC to +7VDC, internally clamped by transient suppressors.
Max distance: 1200m @ 9600 bauds (with 120 ohms balanced cable)

The RS-485 port features MODBUS-RTU protocol. Multiple modules (up to 128) can be paralleled on the
same RS-485 bus for data transfer to automation or building management systems.

The Modbus register list is available FG Wilson

technical support.

The RS-485 port provides also a good solution for distant PC connection where RainbowPlus program
will enable programming, control and monitoring.

For more details about programming, control and

monitoring through RS-485 port please refer to
RainbowPlus user manual.

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FG-100 User Manual Firmware V-5.8

3.12. ETHERNET PORT (OPTIONAL)

Data Flow
led

Link
Established
Ethernet
led
Connector

STANDARD ETHERNET CABLE

Description: IEEE802.3 compliant, 10/100 Base-TX RJ45 ethernet port with

indicating leds
Data rate: 10/100 Mbits/s, auto detecting
Connector: RJ45
Cable type: CAT5 or CAT6
Isolation: 1500 VAC, 1 minute
Max distance: 100m with CAT5 or CAT6 cable
Functionality: Embedded TCP/IP, Web Client, SMTP, e-mail, SNMP, Modbus
TCP_IP

LED FUNCTIONS:
GREEN: This led turns on when the ethernet link is established (connector inserted)
YELLOW: This led blinks when data transfer occurs inwards or outwards. Periodic blinking will witness
data flow.

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FG-100 User Manual Firmware V-5.8

4. TOPOLOGIES

Various topologies are selectable through program parameter.

In following drawings the connections are shown for the alternator. Current transformers are supposed
connected to the alternator side.

4.1. SELECTING THE TOPOLOGY

Generator
Parameters
s

Topology
Selection

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FG-100 User Manual Firmware V-5.8

4.2. 3 PHASE, 4 WIRE, STAR

4.3. 3 PHASE, 3 WIRE, DELTA

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FG-100 User Manual Firmware V-5.8

4.4. 3 PHASE, 4 WIRE, DELTA

4.5. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L2)

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FG-100 User Manual Firmware V-5.8

4.6. 3 PHASE, 3 WIRE, DELTA, 2 CT (L1-L3)

4.7. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L2)

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FG-100 User Manual Firmware V-5.8

4.8. 2 PHASE, 3 WIRE, DELTA, 2 CTs (L1-L3)

4.9. 1 PHASE, 2 WIRE

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FG-100 User Manual Firmware V-5.8

5. FUNCTIONALITIES

The same unit provides different functionalities through parameter setting. Thus, a single stock item will
fulfill various duties, minimizing stock cost.

5.1. REMOTE START FUNCTIONALITY

When the Remote Start functionality is selected, the unit will wait for a Remote Start signal from external
controller. Upon reception of this signal, it will run the engine, and provide engine and alternator
instrumentation and fault monitoring.
The unit features both MPU and J1939 CANBUS input options. Thus, both mechanical and electronic
engines are supported.

5.2 ENGINE CONTROLLER FUNCTIONALITY

When the Engine Controller functionality is selected, genset electrical measurements and protections will
be disabled. The unit is supposed to control an engine without alternator.
When the Engine Control Mode is activated:
-the unit will not display genset AC parameters (volts, amps, kW and pf).
-genset voltage and frequency protections are disabled. However engine rpm protections will be
active.
The unit features both MPU and J1939 CANBUS inputs. Thus both mechanical and electronic engines
are supported.

It is strongly recommended to wire speed detection

through J1939-CANBUS or MPU and enter correct
low and high rpm limit values in order to preserve
engine speed protection.

If J1939-CANBUS is not available on the engine, an

external overspeed protection device is strongly
recommended.

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FG-100 User Manual Firmware V-5.8

6. CONNECTION DIAGRAMS

6.1. REMOTE START FUNCTIONALITY

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FG-100 User Manual Firmware V-5.8

6.2. ENGINE CONTROL FUNCTIONALITY

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FG-100 User Manual Firmware V-5.8

7. TERMINAL DESCRIPTION

Term Function Technical data Description

1 BATTERY POSITIVE +12 or 24VDC The positive terminal of the DC Supply.
2 BATTERY NEGATIVE O VDC Power supply negative connection.
3 DIGITAL OUTPUT 1 Protected This relay has programmable function,
Semiconductor selectable from a list. Factory set as
Outputs CRANK output.
4 DIGITAL OUTPUT 2 1A/28VDC This relay has programmable function,
selectable from a list. Factory set as FUEL
output.
5 DIGITAL OUTPUT 3 This relay has programmable function,
selectable from a list. Factory set as
PREHEAT output.
6 DIGITAL OUTPUT 4 This relay has programmable function,
selectable from a list. Factory set as
ALARM output.
7 DIGITAL OUTPUT 5 This relay has programmable function,
selectable from a list. Factory set as
ENGINE RUNNING output.
8 CHARGE Input and output Connect the charge alternator’s D+
terminal to this terminal. This terminal will
supply the excitation current and measure
the voltage of the charge alternator.

Term Function Technical data Description

9 DIGITAL INPUT 1 Digital Inputs, The input has programmable function.
0-30Vdc Factory set as LOW OIL PRESSURE
SWITCH.
10 DIGITAL INPUT 2 The input has programmable function.
Factory set as HIGH TEMP SWITCH.
11 DIGITAL INPUT 3 The input has programmable function.
Factory set as REMOTE START.
12 DIGITAL INPUT 4 The input has programmable function.
Factory set as SPARE ALARM 1.
13 DIGITAL INPUT 5 The input has programmable function.
Factory set as SPARE ALARM 2.
14 DIGITAL INPUT 6 The input has programmable function.
Factory set as EMERGENCY STOP.

Term Function Technical data Description

15 CANBUS-H Digital communication Connect the J1939 port of an electronic
port engine to these terminals. The 120 ohm
16 CANBUS-L terminating resistors are inside the unit.
Please do not connect external resistors.
17 CANBUS-GROUND Use a twisted cable pair or coaxial cable
for best results.

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FG-100 User Manual Firmware V-5.8

Term Function Technical data Description

51 GEN-L1 Generator phase Connect the generator phases to these
52 GEN-L2 inputs, 0-300V-AC inputs. The generator phase voltages
53 GEN-L3 upper and lower limits are programmable.
54 GENERATOR NEUTRAL Input, 0-300V-AC Neutral terminal for the generator phases.

Term Function Technical data Description

55 CURR_1+ Current transformer Connect the generator current transformer
inputs, 5A-AC terminals to these inputs.
56 CURR_1- Do not connect the same current
transformer to other instruments otherwise
57 CURR_2+ a unit fault will occur.
Connect each terminal of the transformer
to the unit’s related terminal.
58 CURR_2-
Do not use common terminals. Do not use
grounding.
59 CURR_3+ Correct polarity of connection is vital.
The rating of the transformers should be
60 CURR_3- identical for each of the 3 phases.
The secondary winding rating shall be 5
Amperes. (ex: 200/5 Amps).

Term Function Technical data Description

61 SENDER SUPPLY +5V Output This terminal provides +5V supply for
active type senders. The maximum output
current is 50mA. An internal electronic
fuse protects the supply against overloads
or short circuits.
62 ANALOG SENDER 1 Analog voltage Connect to the oil pressure sender.
(OIL PRESSURE SENDER) measuring input, Do not connect the sender to other
0.0-5.0VDC devices.
63 ANALOG SENDER 2 Resistor measuring Connect to the coolant temperature
(COOLANT TEMP. SENDER) input, sender. Do not connect the sender to
0-5000 ohms other devices.
64 ANALOG SENDER 3 Connect to the fuel level sender.
(FUEL LEVEL SENDER) Do not connect the sender to other
devices.
65 SENDER GROUND Input Ground potential for analog senders.
Connect to the engine body, close to
senders.

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FG-100 User Manual Firmware V-5.8

8. TECHNICAL SPECIFICATIONS

DC Supply Range: 8.0 to 36.0 V-DC.

Current consumption: 200 mA-DC max @ 12V-DC
Topology: 1-2-3 phases, with or without neutral
Alternator voltage: 0 to 300 V-AC (Ph-N)
Alternator frequency: 0-100 Hz.
VT Range: 0.1/1 to 6500 / 1
Current Inputs: from current transformers. ../5A.
CT Range: 5/5A to 5000/5A
V-A-cos Accuracy: 0.5% + 1 digit
kW Range: 0.1kW to 65000 kW
Accuracy:
Voltage: 0.5%+1digit
Current: 0.5%+1 digit
Frequency: 0.5%+1 digit
Power(kW,kVAr): 1.0%+2digit
Power factor: 0.5 %+1digit
Digital inputs: input voltage 0 to 36 V-DC.
Analog input range: 0-5000 ohms.
DC Outputs: Protected mosfet semiconductor outputs, rated 1Amp@28V-DC
Cranking dropouts: survives 0V for 100ms.
Charge Alternator Excitation: 100mA @12VDC, 200mA @24VDC
Display Screen: 2.9”, 128x64 pixels
USB Device: USB 2.0 Full speed
Operating temperature: -20°C to 70°C (-4 to +158 °F)
-40°C to 70°C (-40 to +158°F) with optional display heater
Storage temperature: -40°C to 80°C (-40 to +176°F)
Maximum humidity: 95% non-condensing.
IP Protection: IP65 from front panel, IP30 from the rear (with gasket)
Dimensions: 133 x 107 x 46mm (WxHxD)
Panel Cut-out Dimensions: 117 x 87 mm minimum.
Weight: 200 g (approx.)
Case Material: High Temperature, non-flammable ABS/PC (UL94-V0)
Installation: Flat surface mounting on a Type 1 enclosure. Rear retaining plastic brackets.

EU Directives Conformity
-2014/35/EC (low voltage)
-2014/30/EC (electro-magnetic compatibility)
Norms of reference:
EN 61010 (safety requirements)
EN 61326 (EMC requirements)

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FG-100 User Manual Firmware V-5.8

9. DESCRIPTION OF CONTROLS

9.1. FRONT PANEL FUNCTIONALITY

Graphic LCD
screen
Next screen
Fault condition
group.
indicators
LAMP TEST if
held pressed

Mimic Diagram
(sysem status) Next screen in
the same group.
ALARM Mute

RUN mode STOP mode AUTO mode

button button button

When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the
service request output function will be active. The service request can also create a fault condition of any
level following parameter setting.
The service request output function may be assigned to any digital output using Relay Definition
program parameters.

To turn off the SERVICE REQUEST led, and reset the service
period, press together the OFF and LAMP TEST keys for 5
seconds.

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FG-100 User Manual Firmware V-5.8

9.2. PUSHBUTTON FUNCTIONS

BUTTON FUNCTION
Selects RUN mode. The genset runs off-load.
If held pressed for 5 seconds, selects TEST mode. In TEST mode the
genset runs and takes the load.

Selects AUTO mode. The genset runs on REMOTE START signal status.

Selects OFF mode. The genset stops.

Selects next screen group.

LAMP TEST when held pressed.

Selects next display screen in the same group.

Resets the ALARM RELAY.

When held pressed for 5 seconds, enters PROGRAMMING mode.

Makes factory reset. Please review chapter RESETTING TO FACTORY

DEFAULTS for more details.

When held pressed for 5 seconds, resets service request counters. Please
review chapter SERVICE REQUEST ALARM for more details.

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FG-100 User Manual Firmware V-5.8

9.3. DISPLAY SCREEN ORGANIZATION

The unit measures a large number of electrical and engine parameters. The display of the parameters is
organized as PARAMETER GROUPS and items in a group.

Navigation between different groups are made with button.

Each depression of the button will cause the display to switch to the next group of parameters. After
the last group the display will switch to the first group.

Navigation inside a group is made with button.

Each depression of the button will cause the display to switch to the next parameter in the same
group. After the last parameter the display will switch to the first parameter.
Below is a basic list of parameter groups:
Genset Parameters: Genset voltages, currents, kW, kVA, kVAr, pf etc...
Engine Parameters: Analog sender readings, rpm, battery voltage, engine hours, etc...
J1939 Parameters: Opens only if the J1939 port is enabled. The unit is able to display a long list of
parameters, under the condition that the engine sends this information. A complete list of available
readings is found at chapter J1939 CANBUS ENGINE SUPPORT.
Alarm Display: This group displays all existing alarms, one screen per alarm. When there is no more
alarm to display it will show “END OF ALARM LIST”.
GSM Modem Parameters: Signal strength, counters, communication status, IP addresses etc...
Ethernet Parameters: Ethernet connection status, counters, IP addresses etc...
Status & Counters Groups: This group includes various parameters like genset status, service
counters, firmware version etc...

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FG-100 User Manual Firmware V-5.8

9.4. MEASURED PARAMETERS

The unit performs a detailed set of AC measurements.

Mains currents and power parameters (listed in blue color) are measured and displayed only if CTs are
placed at load side. please see connection diagrams section for more details.
The list of measured AC parameters is below:
Gen voltage phase L1 to neutral Gen kW phase L1
Gen voltage phase L2 to neutral Gen kW phase L2
Gen voltage phase L3 to neutral Gen kW phase L3
Gen average voltage phase to neutral Gen total kW
Gen voltage phase L1-L2 Gen kVA phase L1
Gen voltage phase L2-L3 Gen kVA phase L2
Gen voltage phase L3-L1 Gen kVA phase L3
Gen frequency Gen kVAr phase L1
Gen current phase L1 Gen kVAr phase L2
Gen current phase L2 Gen kVAr phase L3
Gen current phase L3 Gen pf phase L1
Gen average current Gen pf phase L2
Gen pf phase L3
Gen total pf
Gen Neutral current

Below engine parameters are always measured:

Engine speed (rpm)
Battery voltage,

The unit features 3 analog senders, fully configurable for the name and function.
Below is a typical list of analog senders, capable of changing following configuration:
Coolant temperature
Oil pressure (bar, kPa)
Fuel level (%, lt)

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 FG-100 User Manual Firmware V-5.8

9.5. LED LAMPS

Alarm indicator

Warning indicator

Service request
indicator

FLASH: Genset
running
ON: Genset
Contactor on

RUN mode STOP mode AUTO mode

indicator indicator indicator

STATUS LEDS:
ALARM: Turns on when a shutdown fault condition exists.
WARNING: Turns on when a warning fault condition exists.
SERVICE REQUEST: Turns on when at least one of the service counters has expired.
GENSET: Flashes when all genset phase voltages and the genset frequency are within limits. If
enabled, the genset phase rotation order must be also right. Turns on when the GENSET
CONTACTOR is activated.
MODE LEDS: Each led turns on when the related mode is selected, either locally or remotely.

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FG-100 User Manual Firmware V-5.8

10. DISPLAYING EVENT LOGS

The unit features more than 400 event logs with date-time stamp and full snapshot of measured values at
the moment that the event has occurred.
Stored values in an event record are listed below:
-event number
-event type / fault definition (see below for various event sources)
-engine hours
-operation mode
-operation status (on-load, on-mains, cranking, etc...)
-engine hours run
-genset phase voltages: L1-L2-L3
-genset phase currents: L1-L2-L3
-genset frequency
-genset total active power (kW)
-genset total power factor
-oil pressure
-engine temperature
-fuel level
-oil temperature
-canopy temperature
-ambient temperature
-engine rpm
-battery voltage
-charge voltage

Possible event sources are various. Every source can be individually enabled or disabled:

Event enable
selection tab

Program mode entrance event: recorded with the password level when program mode is entered.
Mode change event: recorded when the operation mode is changed.
Shutdown/loaddump/warning events: recorded when the related fault condition occurs.
Remote Start/Remote Stop events: recorded when mains status is changed
Engine started/stopped events: recorded when engine status is changed
Genset on_load/off_load events: recorded when the genset loading status is changed

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FG-100 User Manual Firmware V-5.8

Event logs are also displayed within the main screen. Press button to find event record screen.

When displaying event logs, button will display the next event.
Alarms are displayed with their numbers and engine hour on event log screen.

Press to navigate
between screens.

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FG-100 User Manual Firmware V-5.8

11. STATISTICAL COUNTERS

The unit provides a set of non-resettable incremental counters for statistical purposes.
The counters consist on:
-total genset kWh
-total genset kVArh inductive
-total genset kVArh capacitive
-total genset export kWh

-total engine hours

-total engine starts
-total fuel filled in the tank

-engine hours to service-1

-time to service-1
-engine hours to service-2
-time to service-2
-engine hours to service-3
-time to service-3

These counters are kept in a non-volatile memory and are not affected from power failures.

11.1. FUEL CONSUMPTION MONITORING

The unit is capable to display the actual fuel consumption of the engine through J1939 fuel consumption
information
If the engine is sending the fuel rate through J1939 messaging, then the unit will directly display the fuel
consumption information coming from the ECU.
Related parameters are:
Required Description
Parameter Definition Unit Min Max
Value
Fuel Counter Unit Lt/gal - - any This is the unit for the fuel counter

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FG-100 User Manual Firmware V-5.8

12. OPERATION OF THE UNIT

12.1. QUICK START GUIDE

STOPPING THE ENGINE: Press STOP button

STARTING THE ENGINE: Press RUN button

LOAD TEST: Hold pressed RUN button for 5 seconds. The genset will run and take the load.

AUTOMATIC OPERATION: Press AUTO button.

Mode can be changed anytime without negative effect.

Changing the operation mode while the genset is running will
result into a behavior suitable for the new operating mode.

12.2. STOP MODE

The STOP mode is entered by pressing the button.

In this mode, the genset will be in a rest state.
When STOP mode is selected, if the genset is running under load, then it will be immediately unloaded. The
engine will continue to run during Cooldown Timer and will stop afterwards.
If the STOP button is pressed again, then the engine will immediately stop.
If the engine fails to stop after the expiration of Stop Timer then a Fail to Stop warning will occur.
If a Remote Start signal arrives in STOP mode, the genset will not start until AUTO mode is selected.

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FG-100 User Manual Firmware V-5.8

12.3. AUTO MODE

The AUTO mode is entered by pressing the button.

The controller will constantly monitor the REMOTE START signal availability. It will run the engine when the
remote start signal arrives.

If a panel lock input is defined and signal is applied, then mode

change will not occur. However, display navigation buttons are
still enabled and parameters may be visualized.

When REMOTE START signal arrives then an engine start sequence begins:
 The unit waits during Engine Start Delay for skipping short mains failures. If the mains is restored
before the end of this timer, the genset will not start.
 The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.
 The engine will be cranked for programmed times during crank timer. When the engine fires, the
crank relay will be immediately deactivated. See section Crank Cutting for more details.
 The engine will run at idle speed during Idle Speed Timer.
 The engine will run unloaded during engine heating timer.
 If alternator phase voltages, frequency and phase order are correct, the unit will wait for the
generator contactor period and the generator contactor will be energized.
When REMOTE START signal goes off then an engine stop sequence begins:
 The engine will continue to run for the mains waiting period to allow mains voltages to stabilize.
 Then the generator contactor is deactivated and the mains contactor will be energized after mains
contactor timer.
 If a cooldown period is given, the generator will continue to run during the cooldown period.
 Before the end of cooldown, the unit will reduce the engine speed to idle speed.
 At the end of cooldown, the fuel solenoid will be de-energized, the stop solenoid will be energized for
Stop Solenoid timer and the diesel will stop.
 The unit will be ready for the next mains failure.

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12.4. RUN MODE, MANUAL CONTROL

The RUN mode is entered by pressing the button.

When the RUN mode is selected, the engine will be started regardless of the REMOTE START signal.
The starting sequence is as described below:
 The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.
 The engine will be cranked for programmed times during crank timer. When the engine fires, the
crank relay will be immediately deactivated. See section Crank Cutting for more details.
 The engine will run at idle speed during Idle Speed Timer.
 The engine will run unloaded until another mode is selected..
 The load can be transferred to the genset by selecting TEST mode.

In order to stop the engine press button or select another mode of operation.

12.5. TEST MODE

The TEST mode is entered by holding pressed the button for 5 seconds.
The TEST mode is used in order to test the genset under load.
Once this mode is selected, the engine will run as described in the RUN mode, regardless of the REMOTE
START signal and the load will be transferred to the genset.
The genset will feed the load indefinitely unless another mode is selected.

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FG-100 User Manual Firmware V-5.8

13. PROTECTIONS AND ALARMS

The unit provides 3 different protection levels, being warnings, loaddumps and shutdown alarms.
1- SHUTDOWN ALARMS: These are the most important fault conditions and cause:
- The ALARM led to turn on steadily,
- The genset contactor to be released immediately,
- The engine to be stopped immediately,
- The Alarm digital output to operate.
2- LOAD_DUMPS: These fault conditions come from electrical trips and cause:
- The ALARM led to turn on steadily,
- The genset contactor to be released immediately,
- The engine to be stopped after Cooldown period,
- The Alarm digital output to operate.
3- WARNINGS: These conditions cause:
- The WARNING led to turn on steadily,
- The Alarm digital output to operate.

If a fault condition occurs, the display will automatically

switch to the ALARM LIST page.

Alarms operate in a first occurring basis:

-If a shutdown alarm is present, following shutdown alarms, loaddumps and warnings will not be accepted,
-If a loaddump is present, following loaddumps and warnings will not be accepted,
-If a warning is present, following warnings will not be accepted.

If the ALARM MUTE button is pressed, the Alarm output will be

deactivated; however, the existing alarms will persist and
disable the operation of the genset.

Alarms may be of LATCHING type following programming.

For latching alarms, even if the alarm condition is removed, the alarms will stay on and disable the operation
of the genset.

Existing alarms may be canceled by pressing one of the

operating mode buttons:

Most of the alarms have programmable trip levels. See the programming chapter for adjustable alarm limits.

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FG-100 User Manual Firmware V-5.8

13.1. DISABLING ALL PROTECTIONS

The unit allows any digital input to be configured as “Disable Protections”.

This input configuration is used in cases where the engine is required to run until destruction. This may be
the case under critical conditions like firefighting or other emergency cases.
This input should be configured as a “Warning”. Thus, when protections are disabled, a warning message
will immediately appear on the screen.
When protections are disabled, all shutdown alarms and loaddumps will become warnings. They will
appear on the screen but will not affect genset operation.
The input may be constantly activated, or preferably it may be activated by an external key activated
switch in order to prevent unauthorized activation.

Disabling protections will allow the genset run until destruction.

Place written warnings about this situation in the genset room.

13.2. SERVICE REQUEST ALARM

The SERVICE REQUEST led is designed to help the periodic maintenance of the genset to be made
consistently.
The periodic maintenance is basically carried out after a given engine hours (for example 200 hours), but
even if this amount of engine hours is not fulfilled, it is performed after a given time limit (for example 12
months).
The unit offers 3 independent service counter sets in order to enable different service periods with different
priorities.
The fault level created upon expiration of service timers may be set as Warning, Loaddump or Shutdown.
Thus, different levels of fault conditions may be generated at different overrun levels.
Each service counter set has both programmable engine hours and maintenance time limit. If any of the
programmed values is zero, this means that the parameter will not be used. For example, a maintenance
period of 0 months indicates that the unit will request maintenance only based on engine hours, there will be
no time limit. If the engine hours is also selected as 0 hours this will mean that this service counter set is not
operative.
When the engine hours OR the time limit is over, the SERVICE REQUEST led (red) will start to flash and the
service request output function will be active. The service request can also create a fault condition of any
level following parameter setting.
The service request output function may be assigned to any digital output using Relay Definition
program parameters. Also relays on an extension module may be assigned to this function.

To turn off the SERVICE REQUEST led, and reset the service
period, press together the STOP and LAMP TEST keys for 5
seconds.

The remaining engine hours and the remaining time limits are kept stored in a non-volatile memory and are
not affected from power supply failures.
The time and engine hours to service are displayed in the GENSET STATUS menu group.

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FG-100 User Manual Firmware V-5.8

13.3. LIST OF ALARMS

Alarms are displayed with their numbers. Thus, a reference list is necessary to decrypt the alarm details.
The unit has 256 shutdown alarms, 256 loaddump alarms and 256 warnings. Thus, a total of 768 different
alarms may be displayed.
• Warnings are displayed with (!e) prefix.
• Shutdowns and loaddumps are displayed with (Xe) prefix.
A sample Alarm: !e0569 = High Engine Temperature Warning

All warnings can be made latching by enabling a single program

parameter: Controller Configuration >Latch All Warnings

Latch All Warnings

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FG-100 User Manual Firmware V-5.8

ALARM # LOADDUMP# WARNING# DESCRIPTION

0-47 256-303 512-559 DIGITAL INPUT ALARM:
Alarm becomes active when a fault is detected from the
related digital input. Digital inputs are programmable for
the switching polarity, NO/NC contact, latching and
detection delay.
48 304 560 GENSET LOW FREQUENCY:
Set if the generator frequency is below programmed limits.
The fault will be monitored Fault Holdoff Timer delay after
the engine is running. Shutdown and warning limits are
independently programmable. The detection delay is also
programmable.
49 305 561 GENSET HIGH FREQUENCY:
Set if the generator frequency is above programmed limits.
The fault will be monitored Fault Holdoff Timer delay after
the engine is running. Shutdown and warning limits are
independently programmable. The detection delay is also
programmable. Another high frequency shutdown limit
which is 12% above the high limit is always monitored and
stops the engine immediately.
50 306 562 ENGINE LOW RPM:
Set if the engine rpm is below programmed limits. The
faults will be monitored Fault Holdoff Timer delay after the
engine is running. Shutdown and warning limits are
independently programmable. The detection delay is also
programmable. The high rpm overshoot limit is always
monitored and stops the engine immediately.
51 307 563 ENGINE HIGH RPM:
Set if the engine rpm is above programmed limits. The
faults will be monitored Fault Holdoff Timer delay after the
engine is running. Shutdown and warning limits are
independently programmable. The detection delay is also
programmable. The high rpm overshoot limit is always
monitored and stops the engine immediately.
52 308 564 GENSET LOW VOLTAGE:
Set if any of the generator phase voltages goes below
programmed limits for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine
is running.
53 309 565 GENSET HIGH VOLTAGE:
Set if any of the generator phase voltages goes above
programmed limits for Voltage Fail Timer. This fault will be
monitored with Fault Holdoff Timer delay after the engine
is running.
54 310 566 LOW OIL PRESSURE:
Set if the oil pressure value measured from the sender is
below the programmed limit. Warning and shutdown limits
are independently programmable. This fault will be
monitored Holdoff Timer delay after the engine is running.

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FG-100 User Manual Firmware V-5.8

ALARM # LOADDUMP# WARNING# DESCRIPTION

55 311 567 HIGH OIL PRESSURE:
Set if the oil pressure value measured from the sender is
above the programmed limit. Warning and shutdown limits
are independently programmable. This fault will be
monitored Holdoff Timer delay after the engine is running.
56 312 568 LOW COOLANT TEMPERATURE:
Set if the coolant temperature value measured from the
sender is below the programmed limit. Warning and
shutdown limits are independently programmable.
57 313 569 HIGH COOLANT TEMPERATURE:
Set if the coolant temperature value measured from the
sender is above the programmed limit. Warning and
shutdown limits are independently programmable.
58 314 570 LOW FUEL LEVEL:
Set if the fuel level value measured from the sender is
below the programmed limit. Warning and shutdown limits
are independently programmable.
59 315 571 HIGH FUEL LEVEL:
Set if the fuel level value measured from the sender is
above the programmed limit. Warning and shutdown limits
are independently programmable.
60 316 572 OIL SENDER OPEN:
Set if the resistor value read from the sender input is
above 5000 ohms or if the terminal is left open.
61 317 573 TEMPERATURE SENDER OPEN:
Set if the resistor value read from the sender input is
above 5000 ohms or if the terminal is left open.
62 318 574 FUEL LEVEL SENDER OPEN:
Set if the resistor value read from the sender input is
above 5000 ohms or if the terminal is left open.
63 319 575 LOW BATTERY VOLTAGE:
Set if the genset battery voltage is below programmed
limits. Shutdown and warning limits are independently
programmable. The detection delay is also programmable.
64 320 576 HIGH BATTERY VOLTAGE:
Set if the genset battery voltage is above programmed
limits. Shutdown and warning limits are independently
programmable. The detection delay is also programmable.
65 321 577 FAIL TO START:
Set if the engine is not running after programmed number
of start attempts.
66 322 578 FAIL TO STOP:
Set if the engine has not stopped before the expiration of
the Stop Timer.
67 323 579 LOW CHARGE VOLTAGE:
Set if the charge alternator voltage is below the
programmed limit. This fault will be monitored with Fault
Holdoff Timer delay after the engine is running.

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FG-100 User Manual Firmware V-5.8

ALARM # LOADDUMP# WARNING# DESCRIPTION

68 324 580 J1939 ECU FAIL:
Set if no information has been received during Message
Absence Timer from the ECU of the electronic engine.
This fault condition is only controlled when fuel is on.
69 325 581 OVERCURRENT:
Set if at least one of the genset phase currents goes over
the Overcurrent Limit for the period allowed by the IDMT
curve setting. The allowed timer is dependent of the
overcurrent level. If currents go below the limit before
expiration of the timer then no alarm will be set. Please
check chapter Overcurrent Protection (IDMT) for more
details.
70 326 582 OVERLOAD:
Set if the genset power (kW) supplied to the load goes over
the Overload limit for Overload Timer. If the power goes
below the limit before expiration of the timer then no alarm
will be set.
71 327 583 REVERSE POWER:
Set if the genset power (kW) is negative and goes over the
Reverse Power limit for Reverse Power Timer. If the
power goes below the limit before expiration of the timer
then no alarm will be set.
72 328 584 GENSET PHASE ORDER FAIL:
Set if the fault is enabled and the genset phase order is
reverse.
73 329 585 MAINS PHASE ORDER FAIL:
Set if the fault is enabled and the mains phase order is
reverse.
74 330 586 GENSET CB FAIL TO CLOSE:
Set if the feedback input is defined and the related
contactor block feedback signal is not detected after the
expiration of Contactor Open/Close Fail Timer.
75 331 587 GENSET CB FAIL TO OPEN:
Set if the feedback input is defined and the related
contactor block feedback signal is not detected after the
expiration of Contactor Open/Close Fail Timer.
76 332 588 MAINS CB FAIL TO CLOSE:
Set if the feedback input is defined and the related
contactor block feedback signal is not detected after the
expiration of Contactor Open/Close Fail Timer.
77 333 589 MAINS CB FAIL TO OPEN:
Set if the feedback input is defined and the related
contactor block feedback signal is not detected after the
expiration of Contactor Open/Close Fail Timer.
78 334 590 SERVICE-1 REQUEST:
Set if at least one of the service-1 counters has expired.
In order to reset the service counters please hold pressed
both and buttons during 5 seconds. The screen
will display “Completed!”

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FG-100 User Manual Firmware V-5.8

ALARM # LOADDUMP# WARNING# DESCRIPTION

79 335 591 SERVICE-2 REQUEST:
Set if at least one of the service-2 counters has expired.
In order to reset the service counters please hold pressed
both and buttons during 5 seconds. The screen
will display “Completed!”
80 336 592 SERVICE-3 REQUEST:
Set if at least one of the service-3 counters has expired.
In order to reset the service counters please hold pressed
both and buttons during 5 seconds. The screen
will display “Completed!”
81 337 593 ENGINE RUNNING:
Set if the engine is running while the fuel output is not
energized.
82 338 594 AUTO NOT READY:
Set if the genset is not in AUTO mode or a fault condition
or the weekly schedule prevents the automatic starting of
the genset.

13.4. NON-VISUAL WARNINGS

These warnings are not announced at the device front panel,

however they appear in event logs, transferred to the Scada and
cause SMS and e-mail sending.

FUEL THEFT Engine is not running:

If the fuel level measured from the sender input falls by 20% or more in
one hour, then Fuel Theft warning occurs (the detection delay is 10 sec,
not adjustable).
Engine is running:
If the fuel level measured from the sender input falls by 2x”hourly fuel
consumption percentage” or more, then Fuel Theft warning occurs.
FUEL FILLING If the fuel level measured from the sender input is increased by 20% or
more in one hour, then Fuel Filling non-visual warning occurs (the
detection delay is 10 seconds, not adjustable).
MAINTENANCE DONE Sent when the periodic maintenance counters are manually reset.

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FG-100 User Manual Firmware V-5.8

14. PROGRAMMING

14.1. RESETTING TO FACTORY DEFAULTS

In order to resume to the factory set parameter values:

-hold pressed the STOP, LAMP TEST and ALARM MUTE buttons for 5 seconds,
-“RETURN TO FACTORY SET” will be displayed
-immediately press and hold pressed LAMP TEST button for 5 seconds
-factory set values will be reprogrammed to the parameter memory. “Completed!” is displayed.

Hold pressed pushbuttons

Hold
Pressed
For 5
seconds

Hold pressed
The program mode is used to adjust timers, operational limits and the configuration of the unit.
Although a free PC program is provided for programming, every parameter may be modified through the front
panel, regardless of the operating mode.
When modified, program parameters are automatically recorded into a non-erasable memory and take effect
immediately.
The program mode will not affect the operation of the unit. Thus programs may be modified anytime, even
while the genset is running.

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FG-100 User Manual Firmware V-5.8

14.2. ENTERING THE PROGRAMMING MODE

To enter the program mode, press together buttons for 5 seconds.

When the program mode is entered, below password entry screen will be displayed.

Press 2 buttons
for 5 seconds

A 4 digit password must be entered using buttons.

The buttons modify the value of the current digit. The buttons navigate between digits.
The unit supports 3 password levels. The level_1 is designed for field adjustable parameters. The level_2
is designed for factory adjustable parameters. The level_3 is reserved. It allows recalibration of the unit.
The password level-1 is factory set to ‘1234’ and the password level-2 is factory set to ‘9876’.
If a wrong password is entered, the unit will still allow access to the program parameters, but in read-only
mode.
If password “0000” is entered, only EVENT LOG file will be available.

14.4. MODIFYING PARAMETER VALUE

Increase
parameter
value

Previous
parameter
Decrease
parameter
Long Press:
value
Return to the
upper menu
Next
parameter

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FG-100 User Manual Firmware V-5.8

14.5. PROGRAMMING MODE EXIT

To exit the program mode press STOP button. If no button is pressed during 2 minutes the program
mode will be cancelled automatically.

Press STOP
button to exit
PROGRAM
mode

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FG-100 User Manual Firmware V-5.8

15. PROGRAM PARAMETER LIST

Factory Description
Parameter Definition Unit Min Max
Set
This parameter is used to set LCD
001-LCD Contrast - 30 50 31 contrast. Adjust for the best viewing
angle.
This parameter defines the delay after
002-Fault Holdoff Timer sec 0 120 12 the engine runs and before the fault
monitoring is enabled.
This is the period during which the
ALARM relay is active. If the period is
003-Alarm Relay Timer sec 0 120 60
set to 0, this will mean that the period is
unlimited.
0: In RUN mode, the load will not be
transferred to the genset even if the
004-Emergency Backup mains fails.
- 0 1 0
Operation 1: In RUN mode, the load will be
transferred to the genset if the mains
fails.
005-Exercise Enable -
0: exercise once per week
1: exercise once per month
006-Exercise Period - 0 1 0 The exact exerciser day and time is
adjusted within the EXERCISE
SCHEDULE section.
007-Exercise Off/On 0: Exercise at RUN mode
- 0 1 1
Load 1: Exercise at TEST mode
008-Delayed Simulate 0: delayed simulate mains disabled
- 0 1 0
Mains 1: delayed simulate mains enabled
0: SMS messages disabled
009-SMS Enable - 0 1 0
1: SMS messages enabled
010-GPRS Connection 0: GPRS disabled
- 0 1 0
Enable 1: GPRS enabled
011-Rainbow Scada The unit will update the distant
sec 0 65535 5
Refresh Rate monitoring terminal with this rate.
012-Rainbow Scada This is the port number of the first
- 0 65535 0
Address-1 Port monitoring terminal address.
013-Rainbow Scada This is the port number of the second
- 0 65535 0
Address-2 Port monitoring terminal address.
This is the modbus controller identity
014-Modbus Address - 0 240 1
used in Modbus communication.
0: crank cut is performed through oil
pressure switch and oil pressure sender
015-Oil Pressure Switch
- 0 1 0 reading
Priority
1: crank cut is performed only through
oil pressure switch
Delayed Simulate Mains Operation:
max genset running time after Simulate
016-Flashing Relay ON
min 0 1200 0 Mains signal disappears.
Timer
Dual Genset Systems: flashing relay
ON state duration timer.
017-Flashing Relay OFF Dual Genset Systems: flashing relay
min 0 1200 0
Timer OFF state duration.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
This parameter provides the mains and
genset voltage limits with a hysteresis
feature in order to prevent faulty
decisions.
For example, when the mains are
018-Hysteresis Voltage V-AC 0 30 8
present, the mains voltage low limit will
be used as the programmed low limit.
When the mains fail, the low limit will be
incremented by this value. It is advised
to set this value to 8 volts.
0: Genset control
019-Engine Control Only - 0 1 0
1: Engine control (no alternator)
This parameter is used for frequency to
rpm conversion. For a 1500/1800 rpm
020-Alternator Pole Pairs - 1 8 2
engine select 2. For a 3000/3600 rpm
engine select 1.
This parameter controls SMS sending
when mains voltages status is changed.
021-SMS on Mains
- 0 1 0 No warnings generated.
Change
0: no SMS on mains failed or restored
1: SMS sent on mains failed or restored
This parameter controls SMS sending
when IP address of GPRS connection is
022-SMS on IP Change - 0 1 0 changed. No warnings generated.
0: no SMS on IP change
1: SMS sent on IP change
If the fuel level measured from the
sender input falls below this level, then
023-Fuel Pump Low Limit % 0 100 20
the FUEL PUMP function will become
active.
If the fuel level measured from the
024-Fuel Pump High sender input goes above this level, then
% 0 100 80
Limit the FUEL PUMP function will become
passive.
This parameter controls the activation of
the ALARM output during “Engine Start
025-Warning Before Start - 0 1 1 Delay” timer before engine run.
0: no warning before start
1: warning before start
0: warnings are latching/non-latching on
parameter control
026-Latch all Warnings - 0 1 0 1: all warnings are latched. Even if the
fault source is removed, warnings will
persist until manually reset.
This parameter controls remote control
of the unit through Rainbow, Modbus
027-Remote Control
- 0 1 1 and Modbus TCP/IP.
Enable
0: remote control disabled
1: remote control enabled
This parameter is useful to invert all CT
028-Reverse CT polarities at the same time.
- 0 1 0
Direction 0: normal CT polarity assumed.
1: reverse CT polarity assumed.
029-Change Level-1 Level-1 password may be modified with
- 0000 9999 1234
Password this parameter
030-Change Level-2 Level-2 password may be modified with
- 0000 9999 9876
Password this parameter

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
If no button is pressed during this
031-LCD Backlight period, then the unit will reduce the LCD
min 0 1440 60
Dimming Delay screen backlight intensity in for
economy.
After activation of the fuel pump
function, if the Fuel Pump High Limit
level is not reached, then the fuel pump
032-Fuel Filling Timer sec 0 36000 0
will stop for safety.
If this parameter is set to zero, then the
timer is unlimited.
0: The unit powers up in STOP mode
033-Open with Last
- 0 1 0 1: The unit powers up in the same
Mode
operating mode before power down.
If this parameter is not zero, the unit will
activate the Wait Before Transfer output
function during this timer, before
034-Pre-Transfer Delay sec 0 60 0 initiating a load transfer.
This function is designed for elevator
systems, in order to bring the cabin to a
floor and open doors before transfer.
035-Enable Auto not 0: Auto not Ready Warning disabled
- 0 1 0
Ready Warning 1: Auto not Ready Warning enabled
This parameter controls SMS sending
when the engine runs or stops. No
036-SMS on Engine
- 0 1 0 warnings generated.
Run/Stop
0: no SMS on engine run/stop
1: SMS sent on engine run/stop
037-Dual Genset Equal 0: Equal aging not enabled
- 0 1 0
Aging Enabled 1: Equal aging enabled
038-CT Secondary 0: xxx/5A
- 0 1 0
Rating 1: xxx/1A
If enabled, the unit will generate a non-
visual warning when maintenance
counters are reset. In consequence,
039-Maintenance Done SMS and e-mails will be sent, the
- 0 1 0
Warning Enable warning will be visible on the central
monitoring system.
0: maintenance warning disabled
1: maintenance warning enabled
This parameter adjusts the time zone of
the controller, in order to allow internal
040-Time Zone min -720 +720 0
real time clock to be synchronized to
the UTC time.
0: no location information from GSM
041-GSM Location
- 0 1 0 1: location information read from GSM
Information
system.
0: When Loaddump alarm occurs,
genset contactor opens and genset
runs until the end of the cooldown
042-Disable STOP at
- 0 1 0 period.
Loaddump
1: When Loaddump alarm occurs,
genset contactor opens but the genset
continues running without timeout.
This is the primary/secondary ratio of
043-Current Transformer
- 1 1000 100 current transformers. All transformers
Ratio
must have the same ratio.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
This is the voltage transformer ratio.
044-Voltage Transformer This value will multiply all voltage and
- 0 5000 1.0
Ratio power readings. If transformers are not
used, the ratio should be set to 1.0
The nominal value of genset and mains
V-
045-Nominal Voltage 0 300 230 voltages. Voltage limits are defined by
AC
reference to this value.
The nominal value of genset and mains
046-Nominal Frequency Hz 0 500 50 frequency. Frequency limits are defined
by reference to this value.
When secondary voltage is selected,
V- this is the nominal value of genset and
047-Nominal Voltage-2 0 300 120
AC mains voltages. Voltage limits are
defined by reference to this value.
When secondary frequency is selected,
this is nominal value of genset and
048-Nominal Frequency-2 Hz 0 500 60
mains frequency. Frequency limits are
defined by reference to this value.
When tertiary voltage is selected, this is
V- the nominal value of genset and mains
049-Nominal Voltage-3 0 300 120
AC voltages. Voltage limits are defined by
reference to this value.
When tertiary frequency is selected, this
is nominal value of genset and mains
050-Nominal Frequency-3 Hz 0 500 60
frequency. Frequency limits are defined
by reference to this value.
If one of the genset phase voltages goes
051-Genset Low Voltage under this limit when feeding the load,
% V-100 V+100 V-15%
Warning Limit this will generate a GENSET LOW
VOLTAGE warning.
If one of the genset phase voltages goes
under this limit when feeding the load,
052-Genset Low Voltage
% V-100 V+100 V-20% this will generate a GENSET LOW
Shutdown Limit
VOLTAGE shutdown alarm and the
engine will stop.
If one of the genset phase voltages goes
053-Genset High Voltage over this limit when feeding the load, this
% V-100 V+100 V+15%
Warning Limit will generate a GENSET HIGH
VOLTAGE warning.
If one of the genset phase voltages goes
over this limit when feeding the load, this
054-Genset High Voltage
% V-100 V+100 V+20% will generate a GENSET HIGH
Shutdown Limit
VOLTAGE shutdown alarm and the
engine will stop.
If at least one of the genset phase
055-Genset Voltage Fail voltages goes outside of the limits
sec 0 10 1
Timer during this timer, a genset voltage fault
will occur.
If the genset frequency goes under this
056-Genset Low limit when feeding the load, this will
% F-100 F+100 V-15%
Frequency Warning Limit generate a GENSET LOW
FREQUENCY warning.
If the genset frequency goes under this
limit when feeding the load, this will
057-Genset Low
% F-100 F+100 F-20% generate a GENSET LOW
Frequency Shutdown Limit
FREQUENCY shutdown alarm and the
engine will stop.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
If the genset frequency goes over this
058-Genset High limit when feeding the load, this will
% F-100 F+100 F+15%
Frequency Warning Limit generate a GENSET HIGH
FREQUENCY warning.
If the genset frequency goes over this
059-Genset High limit when feeding the load, this will
Frequency Shutdown % F-100 F+100 F+20% generate a GENSET HIGH
Limit FREQUENCY shutdown alarm and the
engine will stop.
If the genset frequency goes outside of
060-Genset Frequency
sec 0 10 1 the limits during this timer, a genset
Fail Timer
frequency fault will occur.
If the battery voltage falls below this
061-Low Battery Voltage
V-DC 5.0 35.0 12.0 limit, this will generate a LOW
Warning Limit
BATTERY warning.
If the battery voltage falls below this
062-Low Battery Voltage limit, this will generate a LOW
V-DC 5.0 35.0 9.0
Shutdown Limit BATTERY shutdown alarm and the
engine will stop.
f the battery voltage goes over this limit,
063-High Battery Voltage
V-DC 5.0 35.0 29.0 this will generate a HIGH BATTERY
Warning Limit
warning.
If the battery voltage goes over this
064-High Battery Voltage limit, this will generate a HIGH
V-DC 5.0 35.0 30.0
Shutdown Limit BATTERY shutdown alarm and the
engine will stop.
If the battery voltage goes outside of the
065-Battery Voltage Fail
sec 0 10 3 limits during this timer, a battery voltage
Timer
fault will occur.
If any genset phase voltage differs from
the average more than this limit, it will
generate a Voltage Unbalance fault
066-Genset Voltage
% 0 100 0.0 condition. The action taken upon fault
Unbalance Limit
condition is programmable.
If this parameter is set to 0.0 then
voltage unbalance is not monitored
0: no action
067-Genset Voltage 1: shutdown alarm
- 0 3 0
Unbalance Action 2: loaddump alarm
3: warning
If any genset phase current differs from
the average more than this limit, it will
generate a Current Unbalance fault
068-Genset Current
% 0 100 0.0 condition. The action taken upon fault
Unbalance Limit
condition is programmable.
If this parameter is set to 0.0 then
voltage unbalance is not monitored
0: no action
069-Genset Current 1: shutdown alarm
- 0 3 0
Unbalance Action 2: loaddump alarm
3: warning
If the genset power is negative and
goes above this limit then a
070-Genset Reverse REVERSE POWER warning will be
kW 0 50000 0
Power Warning Limit generated. If this parameter is set to
0 then reverse power fault is not
monitored.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
If the genset power is negative and
071-Genset Reverse
kW 0 50000 0 goes above this limit then a REVERSE
Power Loaddump Limit
POWER loaddump will be generated.
If the genset power is negative and over
072-Genset Reverse
sec 0 120 5 limits during this timer, a reverse power
Power Fail Timer
fault will occur.
If one of the genset phase currents goes
over this limit when feeding the load, this
will generate a genset overcurrent fault
073-Genset Overcurrent
Amp 0 50000 0 condition. The action taken upon fault
Limit
condition is programmable. If this
parameter is set to 0 then overcurrent
fault is not monitored.
When secondary voltage is selected, if
one of the genset phase currents goes
over this limit when feeding the load, this
074-Genset Overcurrent will generate a genset overcurrent fault
Amp 0 50000 0
Limit-2 condition. The action taken upon fault
condition is programmable. If this
parameter is set to 0 then overcurrent
fault is not monitored.
When tertiary voltage is selected, if one
of the genset phase currents goes over
this limit when feeding the load, this will
075-Genset Overcurrent generate a genset overcurrent fault
Amp 0 50000 0
Limit-3 condition. The action taken upon fault
condition is programmable. If this
parameter is set to 0 then overcurrent
fault is not monitored.
076-Genset Overcurrent 0: shutdown alarm
- 0 3 0
Action 1: loaddump alarm
This parameter defines the reaction
speed of the overcurrent detector. A
077-Overcurrent Time
0 1 64 16 higher number means higher sensitivity.
Multiplier
Detailed explanation is given at chapter:
“Overcurrent Protection”
If the total genset active power goes over
this limit when feeding the load, this will
078-Genset Overload
kW 0 50000 0 generate a genset overload loaddump
Limit
alarm. If this parameter is set to 0 then
overload fault is not monitored.
If the genset active power is over the
079-Genset Overload
sec 0 120 3 limit during this timer, an overload fault
Fail Timer
will occur.
If the genset power goes below this limit
080-Load Shedding Low then the load shedding relay will be
kW 0 50000 0
Limit deactivated. Review chapter “Load
Shedding” for more details.
If the genset power goes above this
081-Load Shedding High limit then the load shedding relay will be
kW 0 50000 0
Limit activated. Review chapter “Load
Shedding” for more details.
This is the minimum delay between 2
082-Load Add Delay sec 0 240 0 load_add pulses. Review chapter “Load
Shedding” for more details.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
This is the minimum delay required for a
083-Load Subtract-Add load_add pulse after a load_substract
min 0 120 0
Delay pulse. Review chapter “Load Shedding”
for more details.
This is the connection topology of
genset voltages and CTs. Detailed
explanations are given in the chapter:
TOPOLOGIES.
0: 2 phase, 3 wire L1-L2
084-Genset Connection 1: 2 phase, 3 wire L1-L3
- 0 7 5
Topology 2: 3 phase, 3 wire
3: 3 phase, 3 wire, 2CTs L1-L2
4: 3 phase, 3 wire, 2CTs L1-L3
5: 3 phase, 4 wire star
6: 3 phase, 4 wire delta
7: single phase, 2 wire
This is the period after the mains
085-Genset Contactor contactor has been deactivated and
sec 0 600 0.5
Timer before the genset contactor has been
activated.
After the genset MCB_undervoltage coil
is energized and genset
MCB_undervoltage coil timer is
086-Genset MCB Close
sec 0 10 0.5 elapsed, the genset MCB_close relay
Pulse
will be activated during this period.
Review chapter “Motorized Circuit
Breaker Control” for more details.
The genset MCB_open relay will be
087-Genset MCB Open activated during this period.
sec 0 10 0.5
Pulse Review chapter “Motorized Circuit
Breaker Control” for more details.
The genset MCB_undervoltage coil is
energized during this period before the
088-Genset MCB Under
sec 0 10 0.5 genset MCB_close relay is activated.
Voltage Coil Timer
Review chapter “Motorized Circuit
Breaker Control” for more details.
0: shutdown alarm
089-GCB Alarm Level - 0 1 0
1: loaddump alarm
If a genset MCB feedback input is
090-Genset MCB Fail defined and if the genset MCB fails to
sec 0 600 2.0
Timer change position before the expiration of
this timer, then a fault condition occurs.
0: genset phase order checking
disabled
091-Genset Phase Order
- 0 1 0 1: if genset phase order is faulty, then a
Check Enable
genset phase order fail loaddump alarm
is given.
When the genset active power goes
092-Multi Load Subtract over this limit, the controller will start
kW 0 65000 0
Power Level subtracting load as described in chapter
Five Step Load Management.
When the genset active power goes
093-Multi Load Add below this limit, the controller will start
kW 0 65000 0
Power Level adding load as described in chapter
Five Step Load Management.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
If the load stays over the Multi Load
094-Multi Load Subtract Subtract Power Level parameter
sec 0 36000 0
Start Delay during this timer, then 1 step of load is
subtracted.
095-Multi Load Subtract This is the minimum period between
sec 0 36000 0
Wait Delay two load subtract operations.
If the load stays below the Multi Load
096-Multi Load Add Start
sec 0 36000 0 Add Power Level parameter during
Delay
this timer, then 1 step of load is added.
097-Multi Load Add Wait This is the minimum period between
sec 0 36000 0
Delay two load add operations.
If the genset active power goes above
098-Excess power
kW 0 50000 0 this limit then the controller will give an
Warning Limit
Excess Power Warning.
The nominal value of engine rpm. Low-
099-Nominal RPM rpm 0 50000 1500 high rpm limits are defined by
reference to this value.
When secondary frequency is selected,
this is the nominal value of engine rpm.
100-Nominal RPM-2 rpm 0 50000 1800
Low-high rpm limits are defined by
reference to this value.
When tertiary frequency is selected,
this is the nominal value of engine rpm.
101-Nominal RPM-3 rpm 0 50000 1800
Low-high rpm limits are defined by
reference to this value.
If the engine rpm goes under this limit
102-Low RPM Warning
% R-100 R+100 R-10% when feeding the load, this will generate
Limit
a GENSET LOW RPM warning.
If the engine rpm goes under this limit
103-Low RPM Shutdown when feeding the load, this will generate
% R-100 R+100 R-15%
Limit a GENSET LOW RPM shutdown alarm
and the engine will stop.
If the engine rpm goes over this limit
104-High RPM Warning
% R-100 R+100 R+10% when feeding the load, this will generate
Limit
a GENSET HIGH RPM warning.
If the engine rpm goes over this limit
105-High RPM when feeding the load, this will generate
% R-100 R+100 R+15%
Shutdown Limit a GENSET HIGH RPM shutdown alarm
and the engine will stop.
If the engine rpm goes outside of the
106-RPM Fail Timer sec 0 10 3 limits during this timer, an engine
speed fault will occur.
If the engine rpm goes over the “High
RPM Shutdown Limit” by this quantity,
107-Overspeed HRSL HRSL HRSL
% this will generate immediately a
Overshoot Limit -100 +100 +10%
GENSET HIGH RPM shutdown alarm
and the engine will stop.
If the charge alternator voltage goes
108-Low Charge Voltage
V-DC 0 40 6.0 under this limit, a charge alternator
Warning Limit
voltage warning will occur.
If the charge alternator voltage goes
109-Low Charge Voltage under this limit, a charge alternator
V-DC 0 40 4.0
Shutdown Limit voltage shutdown will occur and the
engine will stop.
110-Charge Voltage Fail If the charge alternator voltage goes
Timer under limits during this timer, a charge
sec 0 120 1
alternator voltage fault will occur.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
If it is requested that the engine runs
111-Engine Heating without load until reaching a certain
°C 0 80 0
Temperature temperature, this parameter defines
the temperature.
This is the time between the mains fails
and the fuel solenoid turns on before
112-Engine Start Delay min 0 720 1 starting the genset. It prevents
unwanted genset operation in battery
backed-up loads.
This is the time after the fuel solenoid
is energized and before the genset is
113-Preheat Timer sec 0 30 0 started. During this period the
PREHEAT relay output is energized (if
assigned by Relay Definitions)
This is the maximum start period.
114-Crank Timer sec 1 15 6 Starting will be automatically cancelled
if the genset fires before the timer.
This is the waiting period between two
115-Wait Between Starts sec 1 240 10
start attempts.
116-Engine Heating This is the period used for engine
sec 0 240 4
Timer heating before load transfer.
The genset will not take the load before
engine heating is completed.
0: engine is heated during Engine
117-Engine Heating Heating Timer.
- 0 1 0
Method 1: engine is heated until the coolant
temperature reaches the Engine
Heating Temperature and at least
during the Engine Heating Timer.
This is the period that the generator
118-Cooldown Timer sec 0 600 120 runs for cooling purpose after the load
is transferred to mains.
This is the maximum time duration for
the engine to stop. During this period
the STOP relay output is energized (if
119-Stop Solenoid Timer sec 0 90 10 assigned by Relay Definitions). If the
genset has not stopped after this
period, a FAIL TO STOP warning
occurs.
120-Number of Starts - 1 6 3 Number of Start attempts
This is the control delay of CHOKE
output.
The choke output is activated together
121-Choke Timer sec 0 240 5
with the crank output. It is released
after this delay or when engine runs
(whichever occurs first).
When the engine runs, the Idle output
relay function will be active during this
122-Idle Speed (Run)
sec 0 240 0 timer. While the IDLE output is active,
Timer
low voltage, low frequency and low rpm
checks are disabled.
Before the engine stops, the Idle output
relay function will be active during this
123-Idle Speed (Stop)
sec 0 240 0 timer. While the IDLE output is active,
Timer
low voltage, low frequency and low rpm
checks are disabled.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
While the IDLE period is over, low
voltage, low frequency and low speed
124-Idle Holdoff Timer sec 0 30 10
checks are enabled after the expiration
of this timer.
The gas solenoid of the gas engine (if
125-Gas Solenoid Delay sec 0 240 5 assigned by Relay Definitions) will be
opened after this delay during cranking.
The crank relay output is deenergized
126-Crank Cut Voltage V-AC 0 65000 100 when the genset phase L1 voltage
reaches this limit.
The crank relay output is deenergized
127-Crank Cut
Hz 0 100 10 when the genset frequency reaches this
Frequency
limit.
The crank relay output is deenergized
128-Crank Cut RPM rpm 0 65000 500
when the engine rpm reaches this limit.
The crank relay output is deenergized
129-Crank Cut Charge
V-DC 0 40 6 when the charge alternator voltage
Voltage
reaches this limit.
0: no crank cut with oil pressure
130-Crank Cut with Oil 1: cranking is cut when oil pressure
- 0 1 0
Pressure switch is open or the oil pressure
measured is above shutdown limit.
If crank cutting with oil pressure is
enabled, cranking is cut after this delay
131-Crank Cut with Oil
sec 0 30 2 when oil pressure switch is open or the
Pressure Delay
oil pressure measured is above
shutdown limit.
0: Crank cutting with charge input
132-Charge Input disabled
- 0 1 0
Connected 1: Crank cutting with charge input
enabled
The full capacity of the fuel tank. If this
133-Fuel Tank Capacity Lt 0 65000 0 parameter is zero, the fuel quantity in
the tank is not displayed.
This parameter is the threshold for
sending FUEL THEFT and FUELLING
sms messages.
If this parameter is set to 0, then no
134-Fuel Consumption
% 0 100 0.0 Fuel Theft and Fuelling sms messages
per Hour
will be sent.
If SMS is required, set this parameter to
a value above the hourly fuel
consumption of the genset.
If the coolant temp is above this limit
135-Coolant Cooler On °C 0 250 90 then the cooler relay function will
become active.
If the coolant temp is below this limit
136-Coolant Cooler Off °C 0 250 80 then the cooler relay function will
become inactive.
If the coolant temp is below this limit
137-Coolant Heater On °C 0 250 50 then the heater relay function will
become active.
If the coolant temp is above this limit
138-Coolant Heater Off °C 0 250 60 then the heater relay function will
become inactive.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
The cooler relay will stay active during
139-Fan Overrun Timer sec 0 240 0 this timer after the coolant temp is below
“Coolant Cooler Off” limit.
The SERVICE REQUEST led indicator
will turn on after this quantity of engine
140-Service-1 Engine hours from the last service. If the period
hours 0 5000 250
Hours is set to ‘0’ no SERVICE REQUEST will
be generated depending on service-1
engine hours.
The SERVICE REQUEST led indicator
will turn on after this amount of time
from the last service. If the period is set
141-Service-1 Period month 0 24 6
to ‘0’ no SERVICE REQUEST will be
indicated depending on Service-1
Period.
0: no action
142-Service-1 Alarm 1: shutdown alarm
- 0 3 3
Level 2: loaddump alarm
3: warning
The SERVICE REQUEST led indicator
will turn on after this quantity of engine
143-Service-2 Engine hours from the last service. If the period
hours 0 5000 250
Hours is set to ‘0’ no SERVICE REQUEST will
be generated depending on service-2
engine hours.
The SERVICE REQUEST led indicator
will turn on after this amount of time
from the last service. If the period is set
144-Service-2 Period month 0 24 6
to ‘0’ no SERVICE REQUEST will be
indicated depending on Service-2
Period.
0: no action
145-Service-2 Alarm 1: shutdown alarm
- 0 3 0
Level 2: loaddump alarm
3: warning
The SERVICE REQUEST led indicator
will turn on after this quantity of engine
146-Service-3 Engine hours from the last service. If the period
hours 0 5000 250
Hours is set to ‘0’ no SERVICE REQUEST will
be generated depending on service-3
engine hours.
The SERVICE REQUEST led indicator
will turn on after this amount of time
from the last service. If the period is set
147-Service-3 Period month 0 24 6
to ‘0’ no SERVICE REQUEST will be
indicated depending on Service-3
Period.
0: no action
148-Service-3 Alarm 1: shutdown alarm
- 0 3 0
Level 2: loaddump alarm
3: warning
0: The J1939 port is inoperative.
1: The analog measurements (oil, temp,
149-J1939 Enable - 0 1 0 and rpm) are picked up from the ECU. If
the ECU communication is lost, then the
engine will be stopped.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
0: GENERIC
1: CUMMINS
2: DETROIT DIESEL
3: DEUTZ
4: JOHN DEERE
5: PERKINS
150-J1939 Engine Brand - 0 15 0 6: VOLVO
7: CATERPILLAR
8: SCANIA
9: IVECO
10: MTU-MDEC
11: BOSCH
Other values: Reserved. Do not use.
GENERIC ENGINE BRAND
0: Generic
CUMMINS ENGINE
0: CM850
1: CM570
DETROIT DIESEL ENGINE
0: Generic
DEUTZ ENGINE
0: Generic
1: EMR2
2: EMR3
JOHN DEERE ENGINE
0: Generic
PERKINS ENGINE
0: Generic
1: ADEM3
2: ADEM 1.3
VOLVO ENGINE
0: Generic
1: without CIU unit
151-J1939 ECU Type - 0 7 0 2: EDC4
CATERPILLAR ENGINE
0: Generic
SCANIA ENGINE
0: Generic
1: S6 (Single Speed)
2: S8 (All Speed)
IVECO ENGINE
0: Generic
1: Vector
2: NEF/CURSOR
MTU-MDEC ENGINE
0: MDEC 302
1: MDEC 201
2: MDEC 303
3: MDEC 304
4: MDEC 506
BOSCH INJECTION SYSTEM
0: Generic
1: EDC 731
2: EDC 9.3
This parameter adjusts the speed of an
152-J1939 Speed Adjust % -100 +100 0.0
ECU controlled engine by +/- 8%.

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FG-100 User Manual Firmware V-5.8

Factory Description
Parameter Definition Unit Min Max
Set
If the battery voltage goes below this
153-Battery Charge Run limit the engine will be automatically
V-DC 0 35.0 0
Voltage started in order to charge the battery
using the charge alternator.
If the battery voltage goes below the
Battery Charge Run Voltage limit, the
154-Battery Charge Run
min 0 1200 0 engine will be automatically run during
Timer
this period in order to charge the battery
using the charge alternator.
After a crank start, messages coming
155-J1939 Message
sec 0 240 3 from the ECU are ignored during this
Suspand Timer
timer.
If no message is received from the ECU
156-J1939 Message
sec 0 240 3 during this timer, then an ECU Fail
Absence Timer
Alarm is generated.
The oil pump is activated prior to the
crank cycle and stopped when this
157-Oil Pump Stop
bars 0 20 0 pressure level is reached.
Pressure
If this value is set to zero, then the oil
pump is not activated.
0: Engine speeed checking is
performed with the RPM information
158-Disable ECU speed coming from the engine ECU unit.
- 0 1 0
control 1: the RPM information coming from the
engine ECU unit is not used for engine
speed checking.
The SPN number written to this
159-J1939 SPN Mask - 0 65535 0 parameter is excuded from engine ECU
alarm list.
The FMI number written to this
160-J1939 FMI Mask - 0 65535 0 parameter is excuded from engine ECU
alarm list
For Volvo engines, when this parameter
is set to 1, then the speed of the engine
161-J1939 Speed toggle - 0 1 0
is switched between 1500 and 1800
rpm.
162-RTC Date - 01 31 Current day of the month.
163-RTC Month - 01 12 Current month.
164-RTC Year - 00 99 Last two digits of the current year.
165-RTC Hours - 00 23 Current hour of the day.
166-RTC Minutes - 00 59 Current minute of the hour.
167-RTC Seconds - 00 59 Current second of the minute.

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FG-100 User Manual Firmware V-5.8

16. CRANK CUTTING

In order to insure fast and reliable crank cutting, the unit uses various resources for engine running
condition detection.
Cranking is stopped when at least one of below conditions is met:
- Crank timer expired:
The crank timer is adjusted through Engine Parameters > Crank Timer. The maximum allowed
timer is 15 seconds.
- Genset AC voltage over threshold:
If the genset phase L1 AC voltage reaches Engine Parameters > Crank Cut Voltage, then
cranking is immediately stopped.
- Genset frequency over threshold:
If the genset phase L1 frequency reaches Engine Parameters > Crank Cut Frequency, then
cranking is immediately stopped.
- Genset rpm over threshold:
If the genset rpm reaches Engine Parameters > Crank Cut RPM, then cranking is immediately
stopped.
- Charge alternator voltage over threshold
Following setting is necessary: Engine Parameters > Charge Input Connected = 1
If the charge alternator voltage reaches Engine Parameters > Crank Cut Charge Voltage, then
cranking is immediately stopped.
- Oil pressure above threshold
Following setting is necessary: Engine Parameters > Crank Cut with Oil Pressure = 1
The crank cutting with oil pressure offers a programmable delay through Engine Parameters >
Crank Cut with Oil Pressure Delay. The parameter is factory set to 2 seconds.
Both low oil pressure switch and oil pressure sender readings may be used for crank cutting. The
oil pressure switch is always used. The sender may be disabled through Controller
Configuration > Oil Pressure Switch Priority parameter.
If enabled, when oil pressure is detected, cranking is stopped after adjustable timer delay.

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FG-100 User Manual Firmware V-5.8

17. OVERCURRENT PROTECTION (IDMT)

The unit offers a programmable IDMT protection function in order to protect the alternator against
excessive currents.
The IDMT (Inverse Definite Minimum Time) protection function has such tripping characteristics that the
tripping time varies inversely with the value of current. Beyond a certain current limit the tripping time
becomes constant (definite) and causes tripping in minimum time.
The tripping formula is defined as below:

Where:
TMS is the IDMT time multiplier setting. This is also the tripping time at 100% overload.
I is the current of the most loaded phase
Iset is the programmed overcurrent limit
t is the tripping time in seconds

Currents below the overcurrent limit are allowed to flow for unlimited time. Currents above the limit will
cause the IDMT protection to trigger with a delay depending on the strength of the overcurrent. Higher the
current, faster the protection will trip.
When a non-tripping overcurrent condition occurs, the unit will keep trace of it. In case of a consecutive
overcurrent, the controller will take into account the residual heat caused by the previous overcurrent and
will trip faster than usual.
The IDMT multiplier adjusts the sensitivity of the IDMT detector. When the multiplier is low, then tripping
will be faster for the same current.
The unit provides separate Overcurrent limits for primary, secondary and tertiary volt/speed/amp settings.
Switching from primary volt/freq/amps to secondary or tertiary values will also switch the IDMT detector to
the secondary/tertiary setting.
The action of the tripping may be selected as a Loaddump (stop after cooldown) or shutdown alarm
(immediate stop).

Screenshot from RainbowPlus configuration program, Generator>Current section

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FG-100 User Manual Firmware V-5.8

Below is a table showing the tripping delay in function of the percent load level (with TMS=36):
100% unlimited 170% 73s 240% 18s
110% 3600s 180% 56s 250% 16s
120% 900s 190% 44s 260% 14s
130% 400s 200% 36s 270% 12s
140% 225s 210% 30s 280% 11s
150% 144s 220% 25s 290% 10s
160% 100s 230% 21s 300% 9s

Below is the tripping delay curve in function of the load level (with TMS=36):

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FG-100 User Manual Firmware V-5.8

18. MOTORIZED CIRCUIT BREAKER CONTROL

The unit offers full control for any brand and model of motorized circuit breakers (MCB).
The MCB control is performed through 3 digital output functions, namely Open, Close and Undervoltage
coil controls. Only 2 of these outputs are used in a single application.
Any digital output can be assigned to MCB control signals through programming menu.

The MCB CLOSE sequence is below:

Activate UV output, wait for undervoltage coil timer (tuv)
Activate CLOSE output, wait for close pulse timer (tcl)
Deactivate CLOSE output

The MCB OPEN sequence is below:

Deactivate UV output
Activate OPEN output, wait for open pulse timer (top)
Deactivate OPEN output

Open Pulse, Close Pulse and Undervoltage Coil timers

are adjusted through programming menu.

If MCB feedback input is defined and the MCB fails to

change position after the expiration of MCB Fail timer,
then a fault condition will occur.

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FG-100 User Manual Firmware V-5.8

MCB modules can be operated by 2 different ways. The unit supports both configurations.
Below is the terminology used:
M: gear motor
PF: ready to close contact
XF: close coil
MX: open coil
MN: undervoltage trip (release)
AUX: auxiliary contacts

MCB WITH OPEN-CLOSE COILS MCB WITH CLOSE-UV COILS

In the diagram at left, relay function assignments should be as below:

OUTx: Mains (or Genset) Close Pulse
OUTy: Mains (or Genset) Open Pulse

In the diagram at right, relay function assignments should be as below:

OUTx: Mains (or Genset) Close Pulse
OUTy: Mains (or Genset) Undervoltage Coil

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FG-100 User Manual Firmware V-5.8

19. J1939 CANBUS ENGINE SUPPORT

The unit offers a special J1939 port in order to communicate with electronic engines controlled by an ECU
(electronic control unit). The J1939 port consists of 2 terminals which are J1939+ and J1939-.
The connection between the unit and the engine should be made with an appropriate balanced 120 ohms
low capacitance coaxial cable. The external conductor should be grounded at one end only.
A 120 ohms termination resistor is installed inside the unit. Please do not connect external resistor.
The J1939 port is activated by setting the program parameter J1939 Enable to 1. The J1939 Engine
Type parameter should be set accordingly. The list of available engines is given at the programming
section.
If the J1939 port is enabled then the oil pressure, coolant temperature and the engine rpm information
are picked up from the ECU unit. If connected, the MPU unit and related analog senders are discarded.
The controller is able to read and display all below parameters, under condition that the engine sends
these information. Most engines send only some of them. If the engine does not send a parameter, the
unit will simply skip it. Thus only available information are displayed.
The complete list of J1939 display parameters is below:
PGN 65253 / SPN 247 Engine Total Hours of Operation
PGN 65257 / SPN 250 Engine Total Fuel Used
PGN 65262 / SPN 110 Engine Coolant Temperature
/ SPN 174 Engine Fuel Temperature 1
/ SPN 175 Engine Oil Temperature 1
PGN 65263 / SPN 100 Engine Oil Pressure
/ SPN 94 Engine Fuel Delivery Pressure
/ SPN 98 Engine Oil Level
/ SPN 101 Engine Crankcase Pressure
/ SPN 109 Engine Coolant Pressure
/ SPN 111 Engine Coolant Level
PGN 65266 / SPN 183 Engine Fuel Rate
/ SPN 184 Engine Instantaneous Fuel Economy
/ SPN 185 Engine Average Fuel Economy
PGN 65269 / SPN 108 Barometric Pressure
/ SPN 171 Ambient Air Temperature
/ SPN 172 Engine Air Inlet Temperature
PGN 65270 / SPN 102 Engine Turbocharger Boost Pressure
/ SPN 105 Engine Intake Manifold 1 Temperature
/ SPN 106 Engine Air Inlet Pressure
/ SPN 107 Engine Air Filter 1 Differential Pressure
/ SPN 173 Engine Exhaust Gas Temperature
PGN 65271 / SPN 158
PGN 61443 / SPN 92 Engine Percent Load At Current Speed
/ SPN 91 Accelerator Pedal Position 1
PGN 61444 / SPN 190 Engine Speed
/ SPN 513 Actual Engine - Percent Torque
/ SPN 512 Driver's Demand Engine - Percent Torque
The J1939 measurements are also available for Modbus operation. Please check chapter Modbus
Communications for more details.
When the fuel output is active, if no information is received from the ECU during last 3 seconds, then the
unit will give a ECU FAIL alarm and stop the engine. This feature prevents uncontrolled engine operation.
The fault conditions of an electronic engine are considered by the unit as warnings and do not cause
engine stop. The engine is supposed protected by the ECU which will stop it when necessary.

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FG-100 User Manual Firmware V-5.8

The electronic engine fault codes are displayed in text within the alarm list table, together with their
SPN-FMI codes. The complete list of fault codes is given in the engine manufacturer’s user manual.
Below is a basic list of fault conditions (x denotes any FMI)

SPN FMI DESCRIPTION

56 x Overspeed shutdown
57 x Low oil pressure shutdown
58 x High engine temp. shutdown
71 x Gain adjust potentiometer fault
75 x Generator speed circuit fault
79 x Frequency adjust potentiometer fault
80 x Droop adjust potentiometer fault
81 x Low oil pressure warning
82 x High engine temp. warning
91 x Accelerator pedal circuit fault
94 x Fuel filter restriction
Fuel pressure sensor fail
97 x Water in Fuel
99 x Oil filter differential pressure fault
98 x Low oil level, High oil level, Oil level sensor fail
100 x Low oil pressure, Oil pressure sensor fail
101 x Crankcase pressure fault
102 x Intake manifold 1 pressure fault
103 x Turbocharger 1 speed fault
105 x Intake manifold temp high, Intake manifold temp
sensor fail
106 x High boost pressure, Turbo outlet pressure sensor
fail
107 x Air filter restriction, Air filter sensor fail
108 x Atmospheric pressure sensor fail
109 x Coolant pressure fault
110 x High coolant temperature, Coolant temperature
sensor fail
111 x Low coolant level, Coolant level sensor fail
153 x Crankcase ventilation fault
158 x Battery voltage failure
164 x High injector activation pressure, Injector activation
pressure sensor fail
168 x Battery 1 voltage fault
172 x High inlet air temperature, High inlet manifold air
temperature, Inlet manifold air temperature sensor
fail
173 x Exhaust gas temp. fault
174 x High fuel temperature, Fuel temperature sensor fail
175 x High oil temperature, Oil temperature sensor fail
190 x Overspeed, Speed sensor loss of signal, Speed
sensor mechanical failure

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FG-100 User Manual Firmware V-5.8

SPN FMI DESCRIPTION

234 x Incorrect ECM software
612 x Engine magnetic speed sensor fault
620 x ECU internal +5V fail
626 x Preheating relay fault
627 x Injector power supply fault
629 x ECU hardware fail
630 x ECU memory fail
633 x Fuel injector valve fault
636 x Camshaft sensor
637 x Flywheel sensor
639 x ECU memory fail
644 x External speed comm. Input fault
647 x Fan control circuit fault
651 x Injector cylinder #1 fault
652 x Injector cylinder #2 fault
653 x Injector cylinder #3 fault
654 x Injector cylinder #4 fault
655 x Injector cylinder #5 fault
656 x Injector cylinder #6 fault
657 x Injector cylinder #7 fault
657 x Injector cylinder #8 fault
677 x Start motor relay fail
723 x Secondary engine speed sensor fail
1075 x Electric lift pump circulation fault
1079 x ECU internal +5V fail
1111 x Check configuration parameters
1265 x Engine oil burn valve fault
1377 x Multiple unit synch. Switch fault
1378 x Engine oil change interval
1384 x Engine commanded shutdown
2000 x ECU failure
2433 x Exhaust gas temp. right manifold
2434 x Exhaust gas temp. left manifold
2791 x Internal EGR fail

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FG-100 User Manual Firmware V-5.8

Below is a basic list of FMI codes.

Please be aware that these codes may differ slightly depending on the engine brand and model.

FMI DESCRIPTION
0 Value too high” Valid data, but above the normal working range
1 “Value too low” Valid data, but below the normal working range
2 “Faulty data” Intermittent or faulty data or
Short circuit to battery voltage, injector high voltage side
3 “Electrical fault” Abnormally high voltage or short circuit to battery
voltage, injector low voltage side
4 “Electrical fault” Abnormally low voltage or short circuit to battery
negative, injector low voltage or high voltage side
5 “Electrical fault” Abnormally low current or open circuit
6 “Electrical fault” Abnormally high current or short circuit to battery
negative
7 “Mechanical fault” Faulty response from mechanical system
8 “Mechanical or electrical fault” Abnormal frequency
9 “Communication fault” Abnormal updating rate or
Open circuit in injector circuit
10 “Mechanical or electrical fault” Abnormally large variations
11 “Unknown fault” Unidentified fault
12 “Component fault” Faulty unit or component
13 “Faulty calibration” Calibration values outside the limits
14 “Unknown fault” Special instructions
15 Data valid but above normal operating range - least severe level
16 Data valid but above normal operating range - moderately severe level
17 Data valid but below normal operating range - least severe level
18 Data valid but below normal operating range - moderately severe level
19 Received network data in error
20 not used (reserved)
21 not used (reserved)
22 not used (reserved)
23 not used (reserved)
24 not used (reserved)
25 not used (reserved)
26 not used (reserved)
27 not used (reserved)
28 not used (reserved)
29 not used (reserved)
30 not used (reserved)
31 Condition exist

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FG-100 User Manual Firmware V-5.8

20. SMS COMMANDS

This feature is not available.

21. SOFTWARE FEATURES

21.1. LOAD SHEDDING / DUMMY LOAD

The load shedding feature consists on the disconnection of the least crucial loads when the genset power
approaches to its limits. These loads will be supplied again when the genset power falls below the
programmed limit. The internal Load Shedding function is always active. Any digital output may be used
as the load shedding output.
The dummy load function consists on the connection of a dummy load if the total genset load is below a
limit and to disconnection of the dummy load when the total power exceeds another limit. The dummy
load function is the inverse of the load shedding function, thus the same output may be used for both
purposes.
It is also possible to control more complex external systems with multiple steps, using LOAD_ADD and
LOAD_SUBSTRACT output functions. Any digital output may be assigned to these signals.
When the load is above the Load Shedding High Limit, the controller will activate the Load Shedding
output.
When the load is below the Load Shedding Low Limit, the controller will release the Load Shedding
output.
The parameters used in Load Shedding feature are in the Electrical Parameters Group:
Load Shedding Low Limit: If the genset power goes below this limit then the load shedding relay will be
deactivated.
Load Shedding High Limit: If the genset power goes above this limit then the load shedding relay will be
activated.

t1: the load goes below the Load Shedding Low Limit, thus the Load Shedding output becomes inactive.
t2: the load goes above the Load Shedding High Limit, thus the Load Shedding output becomes active.
t3: the load goes below the Load Shedding Low Limit, thus the Load Shedding output becomes inactive.

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FG-100 User Manual Firmware V-5.8

21.2. LOAD ADD / SUBTRACT

The load add/subtract output functions are designed to provide control signals for an external, multi-step
load adding/subtracting system.
This external system will add either linearly or by small steps a dummy load that will prevent the genset
from running below the minimum required load level.
The same function may be used in order to supply loads of different priority levels following the available
genset capacity.
When the load is below the Load Shedding Low Limit, the controller will activate the Load Add output.
The external system will increase the load until it goes over the low limit, where the Load Add output will
become inactive.
When the load is above the Load Shedding High Limit, the controller will activate the Load subtract
output. The external system will decrease the load until it goes below the high limit, where the Load
subtract output will become inactive.
There are protection delays between two pulses. These timers help to stabilizing the decision algorithm
and preventing unwanted multiple operations.

The parameters used in Load Shedding feature are in the Electrical Parameters Group:
Load Shedding Low Limit: If the genset power goes below this limit then the load_add relay will be
active.
Load Shedding High Limit: If the genset power goes above this limit then the load_substract relay will
be active.
Load Add Delay: This is the minimum delay between 2 load_add pulses. This is also the minimum delay
between 2 load_substract pulses.
Load Subtract-Add Delay: This is the minimum delay between load_add and load_substract pulses.

t1: the load goes below the Load Shedding Low Limit, thus the Load Add output becomes active.
t2: the load goes above the Load Shedding Low Limit, thus the Load Add output becomes inactive.
t3: the load goes above the Load Shedding High Limit, thus the Load subtract output becomes active.
t4: the load goes below the Load Shedding High Limit, thus the Load subtract output becomes inactive.
t5: the load goes below the Load Shedding Low Limit, but the Load subtract-Add delay is not expired. The
controller waits until expiration of the timer.
t6: the timer is expired and the load is still below the Load Shedding Low Limit, the Load Add output
becomes active.
t7: the load goes above the Load Shedding Low Limit, thus the Load Add output becomes inactive.

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FG-100 User Manual Firmware V-5.8

21.3. FIVE STEP LOAD MANAGEMENT

The controller is able to manage the supply of up to 5 prioritized loads. The loads are supplied starting
from the number #1 (highest priority) and unloaded from the highest number (lowest priority) available.
Protection timers help to stabilizing the decision algorithm and preventing unwanted multiple operations.
When the load is below the Multi Load Add Power Level during Multi Load Add Start Delay, then 1
step of load is added. The minimum wait period between two load_adds is Multi Load Add Wait Delay.
When the load is above the Multi Load subtract Power Level during Multi Load subtract Start Delay,
then 1 step of load is unloaded. The minimum wait period between two load_subtracts is Multi Load
Subtract Wait Delay.
Add and subtract outputs send pulses of 0.25s duration.
The parameters used in Load Shedding feature are in the Electrical Parameters Group:
Multi Load Subtract Power Level: When the genset active power goes over this limit, the controller will
start subtracting load.
Multi Load Add Power Level: When the genset active power goes below this limit, the controller will
start adding load.
Multi Load Subtract Start Delay (tLSD): If the load stays over the Multi Load Subtract Power Level
parameter during this timer, then 1 step of load is subtracted.
Multi Load Subtract Wait Delay (tLSW): This is the minimum period between two load subtract pulses.
Multi Load Add Start Delay (tLAD): If the load stays below the Multi Load Add Power Level parameter
during this timer, then 1 step of load is added.
Multi Load Add Wait Delay (tLAW): This is the minimum period between two load add pulses.

t1: the load goes below the Multi Load Add Power Level.
t2: after Multi Load Add Start Delay the load is still below Multi Load Add Power Level, the Load_Add_1
sends a pulse.
t3: after Multi Load Add Start Delay and Multi Load Add Wait Delay, the load is still below Multi Load Add
Power Level, thus Load_Add_2 output sends a pulse.
t4: the load goes above the Multi Load Subtract Power Level.
t5: after Multi Load Subtract Start Delay, the load is still above Multi Load Subtract Power Level, thus the
Load_Substract_2 sends a pulse.
t6: the load goes above the Multi Load Subtract Power Level.
t7: Multi Load Subtract Wait Delay is already expired. After Multi Load Subtract Start Delay, the load is still
above Multi Load Subtract Power Level, thus the Load_Subtract_1 output sends a pulse.

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21.4. REMOTE START OPERATION

The unit offers the possibility of Remote Start mode of operation. Any digital input may be assigned as
Remote Start Input using Input Function Select program parameters.
The Remote Start signal may be a NO or NC contact, switching to either battery positive or battery negative.
These selections are made using programming menu.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarm from this input.
When a Remote Start input is defined, the mains phases are not monitored. When the Remote Start
signal is present then the mains will be supposed to fail, inversely when the Remote Start signal is
absent then mains voltages will be supposed to be present.
The front panels mimic diagram’s mains LEDs will always reflect the status of the Remote Start input.

21.5. DISABLE AUTO START, SIMULATE MAINS

The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as Disable
Auto Start using Input Function Select program parameters.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarms generated from this input.
The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery
negative. These selections are made using the programming menu.
If the Disable Auto Start input is defined and the input signal is active, the mains phases are not
monitored and supposed to be inside limits. This will prevent the genset from starting even in case of a
mains failure. If the genset is running when the signal is applied, then usual Mains Waiting and Cooldown
cycles will be performed before engine stop. When the Disable Auto Start signal is present, the front
panels mimic diagram’s mains LEDs will reflect the mains voltages as present.
When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides DISABLE AUTO

START and FORCE TO START operations.

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21.6. BATTERY CHARGING OPERATION, DELAYED

SIMULATE MAINS
The Delayed Mains Simulation feature is used in battery backed up telecom systems where batteries are
able to supply the load during a certain period. The genset is requested to run only when battery voltage
drops below the critical level. Once the engine runs, the rectifier system starts charging the batteries and
the battery voltage goes up immediately. Thus the engine should continue to run a programmed period
for effective charging. The critical battery voltage level will be detected by an external unit which provides
the digital Disable Auto Start signal for the genset control unit.
The unit offers an optional Disable Auto Start signal input. Any digital input may be assigned as
Simulate Mains using Input Function Select program parameters.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarms generated from this input.
The Disable Auto Start signal may be a NO or NC contact, switching to either battery positive or battery
negative. These selections are made using the programming menu.
If the Delayed Simulate Mains program parameter is set to 1 and the input signal is active when the
genset is not feeding the load, the mains phases are not monitored and supposed to be inside limits. This
will prevent the genset from starting when the simulate mains signal is present (batteries charged). The
genset will start when mains voltages are out of limits and the simulate mains signal not present.
If the genset is running when the signal is applied, then MAINS SIMULATION will be prevented during
Flashing Relay On Timer program parameter. After this, usual Mains Waiting and Cooldown cycles will
be performed before engine stop. When the SIMULATE MAINS signal is present, the front panels mimic
diagram’s mains LEDs will reflect the mains voltages as present.
When the signal is passive, the unit will revert to normal operation and monitor the mains voltage status.

The REMOTE START operation overrides Disable

Auto Start operation. When both “Remote Start
Operation” and “Delayed Simulate Mains” are
enabled then REMOTE START operation mode is
performed.

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21.7. DUAL GENSET MUTUAL STANDBY OPERATION

Dual genset intermittent operation consists of regular switching of the load between 2 gensets. The use of
2 gensets instead of one is due either to safety purposes in case of a genset failure or to a continuous
operation requesting service stops.
The running period for each genset is adjustable using Flashing Relay On Timer and Flashing Relay
Off Timer program parameters. If the time is adjusted as 0 hours, it will be actually set to 2 minutes for
faster testing purposes.
A flashing relay output function is provided, based on the parameter Flashing Relay On/Off Timers.
Each time the period programmed using Flashing Relay Timer elapses, the relay output will change
position.
The flashing relay function may be assigned to any digital output using Output Configuration program
parameters.
The dual genset intermittent operation uses also the Disable Auto Start feature. Please review related
chapter for a detailed explanation of this feature.

Priority In Dual Genset Mutual Standby Operation:

It may be required that the dual genset system starts the same genset at every mains failure. This is
achieved using the PRIORITY input.
Any digital input may be assigned as Priority using Input Function Select program parameters.
It is also necessary to set the ACTION program parameter of the related input to 3 in order to prevent any
alarms generated from this input.
The Priority signal may be a NO or NC contact, switching to either battery positive or battery negative. These
selections are made using the programming menu.
If a Priority input is defined, then the system will work in priority mode. If the priority signal is applied, the
unit will become master after each mains failure. If the priority signal is not applied, then the unit will
become the slave one and the other genset will start.

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21.8. MULTIPLE VOLTAGE AND FREQUENCY

The unit offers 3 sets of voltage and frequency protection limit values. The user is allowed to switch
between these 3 sets anytime.
This feature is especially useful in multiple voltage or frequency gensets for easy switching between
different operating conditions.
The switching to the second or third set of limit values can be done via digital input signal.

If switching is done with digital input signal, one of digital inputs has to be defined as “2nd Volt-Freq
Select” using “INPUT FUNCTION SELECT“program group.
If third set is used, the one of digital inputs has to be defined as “3 rd Volt-Freq Select” using “INPUT
FUNCTION SELECT“program group.
Below parameters are available for second voltage-frequency selection:
Nominal Voltage
Nominal Frequency
Nominal RPM
Genset Overcurrent Limit

21.9. SINGLE PHASE OPERATION

If the unit is used in a single phase electrical network, it is advised to select the topology as Single
Phase 2 Wires.
When the topology is set to Single Phase 2 Wires, then the unit will measure electrical parameters only
on phases L1 of genset and mains.
Voltage and overcurrent checks will be performed on phases L1 only.
Phases L2 and L3 parameters, as well as phase-to-phase voltages are removed from display screens.

21.10. EXTERNAL CONTROL OF THE UNIT

The unit offers total external control through programmable digital inputs. Any digital input may be
programmed for below functions:
- Force STOP mode
- Force AUTO mode
- Force TEST mode
- Disable Auto Start
- Force to Start
- Fault Reset
- Alarm Mute
- Panel Lock
External mode select signals have priority on mode buttons of the unit. If the mode is selected by external
signal, it is impossible to change this mode with front panel pushbuttons. However if the external mode select
signal is removed, the unit will revert to the last selected mode via pushbuttons.
It is also possible to lock the front panel completely for remote command.

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21.11. ENGINE HEATING OPERATION

Especially on engines without a body heater, or with a failing one, it may be desired that the genset
should not take the load before reaching a suitable temperature. The unit offers 2 different ways of engine
heating.
1. Timer controlled heating:
This operation mode is selected when the Engine Heating Method parameter is set to 0. In this mode,
the engine will run during parameter Engine Heating Timer, and then the genset will take the load.
2. Timer and temperature controlled heating:
This operation mode is selected when the Engine Heating Method parameter is set to 1. In this mode, at
first the engine will run during parameter Engine Heating Timer, then it will continue to run until the
measured coolant temperature reaches the limit defined in parameter Engine Heating Temperature.
When the requested temperature is reached, the load will be transferred to the genset. This operation
mode may be used as a backup to the engine body heater. If the engine body is warm the heating will be
skipped.

21.12. ENGINE IDLE SPEED OPERATİON

It may be required that the engine runs at the idle speed for a programmed duration for engine heating.
The idle operation duration is adjusted with the parameter Idle Speed Timer. The idle speed will be set
by the governor control unit of the engine.
Any digital output may be assigned as IDLE output using Relay Definition program parameters.
The Idle speed operation is performed both in engine start-up and cool-down sequences. Low speed and
low voltage protections are disabled during idle speed operation.

21.13. ENGINE BLOCK HEATER

The unit is able to provide a digital output in order to drive the block heater resistor. The temperature
reference is the coolant temperature measured from the analog sender input.
The block heater output function may be assigned to any digital output using Relay Definition program
parameters.
The engine body temperature limit is adjusted using the parameter Engine Heating Temperature. The
same parameter is used for engine heating operation.
The relay will become active if the body temperature falls to 4 degrees below the limit set by Engine
Heating Temperature. It turns off when the body temperature exceeds Engine Heating Temperature.

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21.14. FUEL PUMP CONTROL

The unit is able to provide a digital output function in order to drive the fuel pump motor.
The fuel pump is used to transfer fuel from the large capacity main tank (if exists), to the genset daily tank
which is generally integrated in the chassis and has a limited capacity.
The fuel level reference is measured through the analog fuel level sender. When the measured fuel level
falls below Fuel Pump Low Limit parameter, the fuel pump output function will become active. When the
fuel level reaches Fuel Pump High Limit parameter, the output function will become passive. Thus the
chassis fuel tank level will be always kept between Fuel Pump Low Limit and Fuel Pump High Limit
parameters.
If the Fuel Pump High Limit is not reached within Fuel Filling Timer duration, then the fuel pump will
stop for safety.
The fuel pump relay function may be assigned to any digital output using Relay Definition program
parameters.

21.15. GAS ENGINE FUEL SOLENOID CONTROL

The unit provides a special function for the fuel solenoid control of a gas engine.
The fuel solenoid of a gas engine is different from a diesel engine. It should be opened after the cranking
has been started and should be closed between crank cycles. The delay between the crank start and
solenoid opening is adjusted using the Gas Solenoid Delay program parameter.
The gas engine fuel solenoid relay function may be assigned to any digital output using Relay Definition
program parameters.

21.16. PRE-TRANSFER SIGNAL

The controller is able to provide a pre-transfer digital output function.
This function is designed for elevator systems, in order to bring the cabin to a floor and open cabin doors
before transfer.
The duration where this output is active is adjusted with the Pre-Transfer Delay parameter.

If the Pre-transfer Delay parameter is not zero, this will delay

transfers by the same amount.

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21.17. CHARGING THE ENGINE BATTERY

The controller offers an automatic charge cycle for the engine battery.
When the engine battery weakens, the genset will run automatically during programmed period in an
unloaded state in order to charge the engine battery, protecting it from total discharge when the genset
has not run for a long time.
Related parameters:
Battery Charge Run Voltage: If this parameter is different from zero and the engine battery voltage falls
below this limit then the controller will run the engine unloaded, in order to charge engine battery. The
running duration is determined by the Battery Charge Run Timer parameter.
Battery Charge Run Timer: This parameter determines the engine battery charge running duration. The
minimum run time is 2 minutes.
Emergency Backup: If this parameter if activated and the mains fails during engine battery charging run,
then the genset will take the load.

21.18. EXTERNALLY CONTROLLED DIGITAL OUTPUTS

The controller offers 16 externally controllable digital output functions.
These output functions have no effect in the operation of the unit; however they can be redirected to any
digital output, allowing remote control of functions or external devices.
The remote control of these outputs are enabled through Modbus, Modbus TCP/IP and Rainbow Scada
remote control functions.
The outputs are in 16 bits of the same Modbus register, placed at address 11559d.

Output statuses are kept in a non-volatile memory and are not

affected by power failures.

Please review the Modbus manual for more details.

21.19. COMBAT MODE

The controller offers a combat mode input function.

When a digital input is defined as Combat Mode and signal applied to this input, the controller will turn off
all led lamps and the backlight illumination 10 seconds after any key is pressed.
When a button is pressed, the illumination will be enabled for 10 seconds.

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21.20. RESETTING THE CONTROLLER

When necessary, the controller may be manually reset by holding the STOP button pressed for 30
seconds.
The manual reset will cause the hardware to be configured following new settings.
It is advised to proceed to a manual reset or power off/on cycle after every hardware configuration
modification.

21.21. ZERO POWER AT REST

In a manual genset, it is possible to reduce the current consumption of the unit down to true zero
Amperes, in order to prevent the battery from discharging.
For “zero power at rest operation”, an external relay and “wake-up” pushbutton is necessary.
A digital output should be set to ZERO POWER RELAY function. An external relay should be driven with
this digital output. The relay contact will feed the controller power supply.
Any digital output may be assigned as zero-power-relay output. Please refer to the relay function list for
the setup.

CONTROLLER
SUPPLY OUTx

Wake-Up Zero Power

pushbutton Relay

BAT+
The controller wakes-up on applying the power through the “wake-up” pushbutton. Then it will
immediately activate the zero power output which will cause the zero power relay to feed the controller.
If the engine is not run, or if the engine stops, a timer of 5 minutes will be counted. At the expiration of the
counter, the controller will deenergize the zero power relay which will cut the power supply. The controller
will wait in a zero-power state until the wake-up pushbutton is depressed again.

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22. DECLARATION OF CONFORMITY

The unit conforms to the EU directives

-2014/35/EC (low voltage)
-2014/30/EC (electro-magnetic compatibility)
Norms of reference:
EN 61010 (safety requirements)
EN 61326 (EMC requirements)

The CE mark indicates that this product complies with the European requirements for safety,
health environmental and customer protection.

23. MAINTENANCE

DO NOT OPEN THE UNIT !

There are NO serviceable parts inside the unit.

Wipe the unit, if necessary with a soft damp cloth. Do not use chemical agents

24. DISPOSAL OF THE UNIT

Following DIRECTIVE 2002/96/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL

of 27 January 2003 on waste electrical and electronic equipment (WEEE) , this unit should be stored and disposed
separately from the usual waste.

25. ROHS COMPLIANCE

The European ROHS directive restricts and prohibits the use of some chemical materials in electronic
devices.

Following the “DIRECTIVE 2011/65/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of
8 June 2011 on the restriction of the use of certain hazardous substances in electrical and
electronic equipment”, this product is listed in annex-I under category: “Monitoring and control
instruments including industrial monitoring and control instruments” and exempted from ROHS
directive.

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26. TROUBLESHOOTING GUIDE

Below is a basic list of most often encountered

troubles. More detailed investigation may be
required in some cases.

AC voltages or frequency displayed on the unit are not correct:

-Check engine body grounding, it is necessary.

-The error margin of the unit is +/- 2 volts.
-If there are faulty measurements only when the engine is running, there may be a faulty charging
alternator or voltage regulator on the engine. Disconnect the charging alternator connection of the
engine and check if the error is removed.
-If there are faulty measurements only when mains are present, then the battery charger may be failed.
Turn off the rectifier fuse and check again.

KW and cosΦ readings are faulty although the Amp readings are correct:

-Current transformers are not connected to the correct inputs or some of the CTs are connected with
reverse polarity. Determine the correct connections of each individual CT in order to obtain correct KW
and cosΦ for the related phase, and then connect all CTs. Please review chapter “AC CURRENT
INPUTS”

Short circuit outputs of unused Current Transformers.

When the REMOTE START signal arrivess fails the unit energizes the fuel solenoid, but does not
start and OIL PRESSURE EXISTS ! message is displayed:

The unit is not supplied with battery (-) voltage at the oil pressure input.
-Oil pressure switch not connected.
-Oil pressure switch connection wire cut.
-Oil pressure switch faulty.
-Oil pressure switch closes too lately. If oil pressure switch closes, the unit will start. Optionally oil
pressure switch may be replaced.

The engine does not run after the first start attempt, then the unit does not start again and OIL
PRESSURE EXISTS ! message is displayed:

-The oil pressure switch closes very lately. As the unit senses an oil pressure, it does not start. When oil
pressure switch closes the unit will start. Optionally the oil pressure switch may be replaced.

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When the AC mains fails, the engine starts to run but the unit gives START FAIL alarm and then
the engine stops:

-The generator phase voltages are not connected to the unit. Measure the AC voltage between
terminals GEN L1-L2-L3 and Generator Neutral at the rear of the unit while the engine is running. A
fuse protecting the generator phases may be failed. A misconnection may be occurred. If everything is
OK, turn all the fuses off, and then turn all the fuses on, starting from the DC supply fuse. Then test the
unit again.

The unit is late to remove engine cranking:

-The generator voltage rises lately. Also the generator remnant voltage is below 15 volts. The unit
removes starting with the generator frequency, and needs at least 15 volts to measure the frequency.
-The unit is also able to cut cranking from charge alternator voltage and oil pressure input. Please read
chapter “CRANK CUTTING”

The unit is inoperative:

Measure the DC-supply voltage between terminals BAT+ and BAT- at the rear of the unit. If OK, turn all
fuses off, then turn all the fuses on, starting from the DC supply fuse. Then test the unit again.

Programming mode can not be entered:

The program lock input disables programming mode entry. Disconnect the program lock input from
battery negative before modification. Do not forget to make this connection again to prevent
unauthorized program modifications.

Some program parameters are skipped:

These parameters are reserved for factory setting and cannot be modified.

AUTO led flashes and the genset does not run when mains fail:

The unit is in Weekly Schedule OFF time. Please check date and time setting of the unit. Please check
also Weekly Schedule program parameters.

The genset runs but does not take the load:

Check that the genset Yellow led is on steadily. Adjust genset voltage and frequency limits if necessary.
Check that the digital output-8 is configured as “Genset Contactor”
Check “Genset Contactor Timer” program parameter.
Check that a Genset Loading Inhibit input signal is not active. Check input functions. If an input is
configured as “Genset Loading Inhibit” then check the signal is not present at this input.

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