GEMPAC Training

Terminations and their functions

Slots

The PPU/GEMPAC housing is divided into board slot positions, the

unit is divided like this:
Position Terminals
Slot #1 1-28
Slot #2 29-36
Slot #3 37-64
Slot #4 65-72
Slot #5 73-89
Slot #6 90-125
Slot #7 98-125
Slot #8 126-133
Besides the slots there is an additional board where the
communication ports are placed. The RS232 PC service port for
the utility software and the display port.
An overview of the terminals can be seen below. The slots are
positioned in the unit as follows (seen from the top of the unit):

Slots

Terminal strip, explanation (QSK45)

For the relay outputs the following terms will be used:

NO means Normally Open
NC means Normally Closed
COM. means common terminal for the relay in question

Slot #1, power supply and binary I/O

Term.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Function Description
Power supply
Power supply
Status out COM PPU, System Healthy
Status out NO PPU, System Healthy
Relay 1 NO Open Breaker
Relay 1 COM Open Breaker
Relay 1 NC
Relay 2 NO Emergency Stop
Relay 2 COM Emergency Stop
Relay 2 NC Emergency Stop Relay 3 NO Circuit breaker trip
Relay 3 COM Circuit breaker trip
Relay 3 NC Circuit breaker trip Relay 4 NO Spare
Relay 4 COM Spare
Relay 4 NC Spare
Relay 5 NO Close Breaker
Relay 5 COM Close Breaker
Relay 5 NC
Optocoupler COM Spare Optocoupler OP 1 Spare Optocoupler OP 2 Spare Digital input CB Tripped
Digital input Emergency Stop Energized
Digital input CB Closed
Digital input CB Open
Digital input Air Flaps
Common J2 (0V)

Ferrule
K3
J2
K3
K102
GY12
GY3
K799
K905
C2
C1

GY10
GY3

K55
K797
X2
X3
K793
J2

Inputs

The inputs 23-27 on slot #1 are control inputs. Terminal 28 is

the common (J2)
Input 23:
CB Tripped, this input will go high when the Air Circuit Breaker connecting the
generator set to the mains Busbar has tripped out on its own over current
protection, for the QSK45 genset this will not indicate a PPU initiated trip or
other auxiliary protection trip.

Input 24:

Input 25:

CB Closed, is energized high when the circuit breaker is in the closed position.

Input 26:

Emergency stop, will be energized high when the system is running normally,
this signal is required to keep relay 2 energized.

CB Open, is energized high when the circuit breaker is in the open position.

Input 27:

Air Flaps, this is energized high when the air flaps are closed.

Relays

5 relays are mounted in the power supply and binary I/O board in
slot #1.
The relays 1-5 are pre-configured.
Relay 1:

Relay 2:

Circuit Breaker Trip: This relay is energized closed to maintain the circuit breaker
under-voltage trip loop; if a circuit breaker trip is required by the PPU this will deenergize the contacts and trip the breaker

Relay 4:

Emergency Stop: This relay is energized closed to maintain the emergency stop loop;
if an emergency stop is required the PPU will de-energize these contacts and stop the
engine.

Relay 3:

Open Breaker, this relay will open the circuit breaker immediately when required

Spare.

Relay 5:

Circuit Breaker Open, this relay will close the circuit breaker if the conditions set in the
PPU are met.

Acknowledge & Reset Alarms

Acknowledge of the alarms is done in one of two ways, either the binary input 96 is
used or the select button on the display (the second will only clear alarms present in
the PPU)
The alarm acknowledge input acknowledges all present alarms and the alarm LED
Will change from flashing to steady light, it will also reset the alarms on the ECM by
closing Relay 7
The display can be used in the alarm information window. This is shown if you press
The INFO pushbutton.
The alarm information window displays one alarm at a time and whether it is
acknowledged or not. If it is unacknowledged, move the cursor to ACK and press
select to acknowledge it.
Use the up and down buttons to step in the alarm list.
When alarm LED is flashing if there are some unacknowledged alarms, when it is on
continuously there are only acknowledged alarms present.

Slot #2, Communication

Can-open
Term.
29
30
31
32
33
34
35
36

Function Description
Can-H
GND
Can-L
Can-H
GND
Can-L
Not used
Not used

The can is based on the can-open protocol

The serial communication line should be terminated at either end
with a resistor equal to the cable impedance, around 100 to 120
Ohms
Use shielded twisted pair cable and ensure that it is properly
earthed.

Slot #3, QSK Load Sharing and Additional Control

Term.
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64

Function

Description Ferrule

Load sharing line Parallel load sharing line

PL2
Load sharing line Parallel load sharing line
PL1
Load sharing line Parallel load sharing line
PL3
External set pointsIn peak lopping mode: Transducer input from
P mains measuring external power setting level
External set points
External power setting level
External set points
External power setting level
Digital input
ECM Common Warning
K613
Digital input
ECM Common Shutdown
K615
Digital input
AVR Over Voltage
K65
Digital input
Excitation Loss K809
Digital input
Fuel Spillage K795
Digital input
Engine Start
K1014
Digital input
Open Breaker Request
K1002
Digital input
Close Breaker Request
K1006
Digital input
Local Control On
K1012
Digital input
Remote Start REMS
Digital input
Manual/Auto Switch
K1016
Digital input
Speed Increase
K1020
Digital input
Speed Down
K1028
Common J2
(0V)
J2
Relay 6 COM
ECM Idle Rated Selector
K705
Relay 6 NO
ECM Idle Rated Selector
K709
Relay 7 COM
Alarm Reset
K705
Relay 7 NO
Alarm Reset
K707
Relay 8 COM
Close Air Flaps K719
Relay 8 NO
Close Air Flaps K1
Relay 9 COM
Spare
Relay 9 NO
Spare

Slot #3, G3 Load Sharing and Additional Control

Term.
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64

Function

Description

Ferrule

Load sharing line Parallel load sharing line

PL2
Load sharing line Parallel load sharing line
PL1
Load sharing line Parallel load sharing line
PL3
External set points
In peak lopping mode: Transducer input from
P mains measuring external power setting level
External set points
External power setting level
External set points
External power setting level
Digital input
Spare
Digital input
Spare
Digital input
AVR Over Voltage
K65
Digital input
Excitation Loss K809
Digital input
Fuel Spillage K795
Digital input
Engine Start
K1014
Digital input
Open Breaker Request
K1002
Digital input
Close Breaker Request
K1006
Digital input
Local Control On
K1012
Digital input
Remote Start REMS
Digital input
Manual/Auto Switch
K1016
Digital input
Speed Increase
K1020
Digital input
Speed Down
K1028
Common J2
(0V)
J2
Relay 6 COM
Spare
Relay 6 NO
Spare
Relay 7 COM
Alarm Reset
K705
Relay 7 NO
Alarm Reset
K707
Relay 8 COM
Close Air Flaps K719
Relay 8 NO
Close Air Flaps K1
Relay 9 COM
Spare
Relay 9 NO
Spare

Engine Shut downs and Controls

There are a number of engine specific shutdowns and

fault indication marshaled at the PPU
Input 43
ECM Common Warning, this is an input from the ECM indicating a
common warning (not used on G3)

Input 44
ECM Common Shutdown, this is an input from the ECM indicating a
common shutdown (not used on G3)

Input 45
AVR Over voltage, this is an input from the AVR indicating an over
voltage, normally this is set in the AVR.

Input 46
Excitation Loss, this is an input from the ACB indicating an excitation
loss on the stator.

Engine Shut downs and Controls

Input 47
Fuel Spillage, this input is from the fuel spillage sensors within the
bund of the genset.

Input 48
Engine Start, if the conditions are met energizing this input
momentarily (300ms+) will begin the engine starting cycle.

Input 49
Open Breaker Request, energizing this input will energize Relay 1
immediately; this function is not inhibited by any other component or
logic.

Input 50
Close Breaker request, this will begin synch and check synch the
generator as required and if programmed allow closing onto a
dead/black Busbar. Note: regardless of the operation of the panel
Manual/Auto/Remote etc, the PPU will always be in control of the
genset during the closing cycle of the breaker, thus preventing
uncontrolled breaker closing.

Engine Shut downs and Controls

Input 51

Input 52

Speed Increase, energizing this input will increase the speed bias output from
the PPU, this is only possible if the Local Control is enabled.

Input 55

Manual/Auto Switch, this is the key switch input from the control panel that
allows the user to run the machine fully automatically.

Input 54

Remote Start, when the set is switched to auto and Local Control Off/ Remote
On , energizing this input will start the generator, subsequent loss of this signal
will then stop the machine.

Input 53

Local Control On, this input is used to allow remote control of the panel, either
via a SCADA system, or AT control system.

Speed decrease, energizing this input will decrease the speed bias output from
the PPU, this is only possible if the Local Control is enabled.

Input 56

Common negative for all digital inputs on Board 3

Engine Shut downs and Controls

Relay 6
ECM Idle Rated Selector, closing this will indicate to the ECM wither
the generator should run at idle speed or nominal speed, this can be
selected automatically using the Starting Time, a time of 0 seconds
means that the PPU will not activate the relay at all.

Relay 7
Alarm Reset, this resets the alarms in the ECM

Relay 8
Close Air Flaps, this relay will energize the air flaps, when this close
signal is returned or the engine speed drops below 30Hz then the relay
will de-energize.

Slot #4, analogue output

Slot #4 is used for governor/AVR outputs.

These outputs are active outputs i.e. they use the internal power supply. The outputs
are galvanically separated from each other and the rest of the unit.

Term.
65
66
67
68
69
70
71
72

Function
Not used
+/-20 mA out
0
Not used
Not used
+/-20 mA out
0
Not used

Description
Speed governor set-point output

AVR voltage set-point output

The current outputs are converted to voltage using a resistor across the terminals
(200ohm will convert the +/-20 mA into +/-4 VDC, for volts control),
(10 ohm will convert the +/-20 mA into +/ 0.2V for Barber Coleman Speed control with
the Cummins ECM)
For different governor control interface requirements please refer to Aggreko
international Product Support department for advise.

Slot #5, AC measuring

Term. Function

Technical data

Ferrule

Description

73
74

I L1 s1
I L1 s2

Generator current
L1

CR
CR2

1/5A AC input

75
76

I L2 s1
IL2 s2

Generator current
L2

CY3
CY2

1/5 A AC input

77
78

I L3 s1
I L3 s2

Generator current
L3

CB
CB2

1/5 A AC input

79

U L1

Generator voltage L1

GR3

Max. 690 VAC

phase
- phase value

80
81

Not used U L2

Generator voltageL2

GY3

Max. 690 VAC

phase
- phase value

82
83

Not used U L3

Generator voltageL3

GB3

Max. 690
VACphase
- phase value

84

U neutral

Generator voltage
neutral

GN2

For land-based

85

applications only
U L1

Bus voltage L1

LR2

Max. 690 VAC

phase
- phase value

86
87

Not used U L2

Bus voltage L2

LY2

Max. 690
VACphase
- phase value

88
89

Not used U L3

Bus voltage L3

LB2

Max. 690 VAC

phase
- phase value

Slot #6 QSK Digital Inputs

Term.
90
91
92
93
94
95
96
97

Function
Common
Digital input
Digital input
Digital input
Digital input
Digital input
Digital input
Digital input

Description
Ferrule
Digital Input Common J2
Low Oil Level
K1048
Low Oil Pressure
K1050
High Water Temp
K1052
Volts Up
K1038
Volts Down
K1040
Mode Enable
K1036
Alarm reset

Slot #6 G3 Digital Inputs

Term.
90
91
92
93
94
95
96
97

Function
Common
Digital input
Digital input
Digital input
Digital input
Digital input
Digital input
Digital input

Description
Digital Input Common
High Water temp
Low Oil Pressure
Low Water press.
Volts Up
Volts Down
Mode Enable
Alarm reset

Ferrule
J2
K1048
K1050
K1052
K1038
K1040
K1036

Slot 6# Description of Functions

Input 90
Board common (J2)

Input 91, 92 and 93

Digital inputs from engine protection

Low oil Pressure
Low level
High water temp.

Input 94-95
Energizing these inputs will instruct the PPU to vary the voltage level
accordingly, by changing the bias output on terminals 70 and 71 to the
AVR.

Input 96
Mode Enable, this changes the control from Manual to automatic, all
volts, speed, power and circuit breaker control are mode by the PPU
the logic is determined by the mode selection.

Slot #7, Analogue and Engine Interface Card.

An engine interface board is mounted in slot #7. It consists of configurable inputs and outputs.

The configuration is done through the utility software and the default settings can be changed to the
relevant settings.

To configure the inputs, upload the parameter list from the PPU and select the input to be
configured. A configuration dialog box appears and the settings can be changed. The standard title
(e.g. 4-20mA in no. 1) can be changed, and the new title will also be shown in the display.

The minimum and maximum values of the 4-20mA input can be adjusted:

Value: Alarm value (e.g. 85C)

Min.: Value corresponding to 4mA (e.g. 0C)
Max: Value corresponding to 20mA (e.g. 100C)

The inverse proportional function is used when the input has inverse proportionality according to
the measured value. This could for instance be when measuring a negative value.

The inputs can be used as a high or low alarm. As a high alarm the alarm appears when the
measured value is higher than the alarm limit, and as a low alarm the alarm appears when the
measured values are lower than the alarm limit.

The binary inputs use 24-volt constant signal. They are not pulse inputs.

Slot #7, Analogue and Engine Interface Card.

The inputs on the GEMPAC units are pre-configured to allow quick connection of a
number of standard measurements, the analogue inputs are also re-configurable to
allow changes to input type.
These are not wired as standard on production generators.
Term.
98
99
100
101
102
103
104
105
106
107
108
109
110
111

S10

Function
Analogue input

Description

Ferrule

Analogue input
Analogue input
Analogue input
Analogue input
Analogue input
Analogue input
Analogue input
Pt100
Pt101
Pt102
Pt103
Pt104
Pt105

Air Inlet Pressure Left

Air Inlet Pressure Right
Air Inlet Pressure Right
Exhaust Gas Temp Left
Exhaust Gas Temp Left
Exhaust Gas Temp Right
Exhaust Gas Temp Right
Air Temp Container
Air Temp Container
Air Temp Container
Air Temp Control panel
Air Temp Control panel
Air Temp Control Panel

Air Inlet Pressure Left

J2
S12
J2
110
111
112
113
104
105
106
107
108
109

Slot #7, Analogue and Engine Interface Card.

Term.

Function

Description

Ferrule

112
113
114
115
116
117
118
119
120
121
122
123
124
125

Tacho input
Tacho input
Digital input
Digital input
Digital input
Digital input
Digital input
Common
Relay 10 COM
Relay 10 NO
Relay 11 COM
Relay 11 NO
Relay 12 COM
Com.

Engine Speed
Engine Speed
Extern/intern set-point power
Extern/intern set-point voltage
Engine Stop
Fan Fail
Spare
Common
Speed Selection
Speed Selection
Engine Run
Engine Run
Engine Start/Crank

MP1
MP2

FF
J2
K725
K723
K705
K1062
K725

Slot #7, Analogue and Engine Interface Card.

Input 114

Input 115

Fan Fail, this will go high if the engine cooling fan circuit breaker trips.

Input 118

Engine Stop, when energized this will begin the engine stopping cycle; the
genset will de-load (if this is not possible then the breaker will open after a set
period 30 seconds plus de-load time); the breaker will open; then the engine will
run for the preset cooling time, default 5 minutes before stopping.

Input 117

Extern/inter set-point voltage, when energized the unit will base its nominal
voltage level on a percentage of a 0-10V input on terminal 42.

Input 116

Extern/inter set-point power, when energized the unit will base its nominal power
level on a percentage of a 0-10V input on terminal 40.

Spare

Input 119

Common for 114 to 118, (J2).

Slot #7, Analogue and Engine Interface Card.

Relay 10
Speed Selection, this allows the PPU to utilize the speed selection
input of the ECM or other connected device this relay is closed when
the Nominal Frequency is set above 55Hz and open when set below
55Hz.

Relay 11
Engine Run, this is the engine run control relay, will close when the
engine is required to run, equivalent to the fuel control relay.

Relay 12
Engine Start/Crank Relay, required to start/crank the diesel generator
starter motor.