Fujian Fu'an Deppblue Electronic Co.,Ltd.

User's manual for GAC608 controller

1、Summary
With high performance MPU, the GAC608 diesel generator set controller is provided
with many advantages, such as impacted structure、small floor space、easy to connection、
high reliability and so on. Additionally, based on overall control, realize all kinds of
automatic protection and site parameter adjustment, and so this device is widely used for
the automatic control system in all kinds of diesel generator set.
2、Performance and characteristics
¾ Automatic start/stop the generator set, alarm and stop the generator set for high
water temperature、low oil pressure、over speed、low speed, etc.
¾ Built-in ATS control unit.
¾ Built-in main power detection unit.
¾ Detect and display the speed of diesel engine、voltage of battery as well as
running time.
¾ Built-in speed/frequency detect unit，can judge the states such as crank success ,
rated running , over speed and low speed.
¾ Built-in preheating and pre-oil supply control.
¾ Can output two different kinds of control signals for oil-break at the simultaneously,
so suitable for different models diesel engine.
¾ With four gun control models which are high-speed start、three-wire solenoid
valve、servo motor and electric speed regulation , etc. So suitable for different gun
control mechanism.
¾ Power supply range（8~35V），suitable for different voltage environment.
¾ Built-in watch dog can never be dead halt , ensuring smooth program execution .
3、Specification
¾ Power supply: 8~35V DC
¾ Input voltage (main power or generator set): 0~300V AC.
¾ Working conditions: Temperature 0~50℃ Humidity (20~90)%
¾ Storage condition: Temperature range -20℃~+60℃
¾ Power consumption: <3W
4、Parameter setting content
P00 Rated speed: 0—1500 1—1800 2—3000 3—3600
P01 Crank success conditions: 0—Generator frequency 1—Magnetic Pickup +
generator frequency
P02 Calculated value for the number of teeth of flywheel.
P03 Set value for the number of teeth of flywheel: 70—255 (Default 125)
P04 Rated voltage: 80-255
P07 Gun control mode: 0—Fixed gun 1—Servo motor control
2—Electromagnet control 3—Electric speed regulation
P08 Time confirm for start signal: 1—255S (Default 2S)
P09 Number of start: 1—9 (Default 3)
P10 Cranking time: 1—15 (Default 5S)
P11 Crank rest time: 5—60 (Default 10S)
P12 Idle running time: 0—255 (Default 30S)

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 Fujian Fu'an Deppblue Electronic Co.,Ltd. User's manual for GAC608 controller
P13 Oil bypass delay time: 10—255 (Default 15S)
P14 Time confirm for stop signal: 1-255 (Default 2S)
P15 High speed cooling time: 10—255 (Default 120S )
P16 Idle speed cooling time: 0—255 (Default 30S)
P17 Stop time : 10—25 (Default 10S)
P18 Pre-heating time: 0—90 (Default 0S)
P19 Transfer rest time: 2—255 (Default 2S)
P20 Generator set switch delay time: 5—255 (Default 5S)
P21 Main power switch delay time: 1—255 (Default 2S)
P22 Calibration point for battery voltage: (12V DC)
P23 Calibration point for battery voltage: (24V DC)
P24 Calibration point for main power voltage: (220V AC)
P25 Main power voltage display
P26 Calibration point for generator voltage: (220V AC)
P27 Generator voltage display
5、Operating
a. Operation panel

MODEL: GAC608

Crank Failure Cooling Low Oil Pressure

High Water Temperature Low Speed Over speed

Emergency Stop /Stop Failure Remote Signal

Fault Signal for Extension Generator Voltage Abnormal

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 Fujian Fu'an Deppblue Electronic Co.,Ltd. User's manual for GAC608 controller

Speed Display Battery Voltage Display Run time Display

Main power Generator set Load Auto

Manual Setting/Reset Manual generator turn on

Manual turn off Manual main power turn on Manual Start

Manual Stop
b. There are manual、automatic and parameter setting models for choose. When under

manual or automatic mode, if press the key by 3S, the machine enters into parameter

setting mode, while re-press key by 3S, exit from parameter setting mode.
c. Manual operation：

Startup：when under manual state, continues to press by 3S，the generator set

shall be started, and judge that if the starting is successful ,rise up to high-speed for running
automatically. After oil bypass delay time, the generator set enters into normal running.
Within oil bypass delay time, the controller carries out detection for running conditions of
generator set without alarm and stop. In the normal running state , if there is any fault, the
generator set shall speed down and stop..

Stop：After the generator set enters into normal running, press by 3s for normal
stop, then the generator set enters into standby state after high-speed and idle speed cooling. If
the generator set has not entered into normal running, it stops immediately.

ATS Manual operation：Continues to press key by 3s，the generator set turn on；

while continues to press key by 3s，the main power turn on；Continues to press
by 3s，if the ATS is three-section type，the ATS returns to middle position，if two-section
type，returns to main power turn on state.
d. Generator set automatic operation
Under automatic mode, if there is any abnormal condition for main power(Power-off、
overvoltage or low voltage)，all these shall be confirmed by starting signal delay, enter into
starting procedure， then enter into normal running after starting、idle speed delay、
speed-up and oil bypass delay. When the starting signal disappears, the generator set
enters into stop procedure after stop signal delay confirmation, and enter into standby state
after high and idle speed cooling.
e. ATS Automatic operation
Under automatic mode, the generator set enters into running state and provide normal
voltage if the start signal is normal, and carry out automatic switching the generator set on
load after generator set switch delay, if there is failure, switch the main power on load
before generator set stop automatically. When the stop signal is completed with delay
confirmation, switch the main power on load automatically.

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 Fujian Fu'an Deppblue Electronic Co.,Ltd. User's manual for GAC608 controller
f. Fault removal
In the processing of running, if there is any failure, generator set will stop by speed

down immediately, and the corresponding indicator is on. Then press the set/reset key ，
the generator set will be reseted from the failure state.
g. Parameter display
Under auto and manual state, the four-digital nixietube can display speed of
generator set、voltage of battery and running time, and the data shall be updated every 1.5s,

you may press or key for parameter selection. If under setting state, the
four-digital nixietube is used for displaying parameter number and value.
h. Parameter setting

Continues to press key by 3s，the controller enters into parameter setting mode,
and the nixietube displays the parameter number like P××（Such as P01、P02），here, press

or key for parameter selection, if the parameter number is selected, press

key，the nixietube shall display the corresponding parameter value, and the controller shall

make the corresponding digital flicker. If the hundreds'digit flickers，press key , the

value shall be reduced by 100，press key, add 100; if the tens’digit flickers press

key, the value is added with 10, while press key, the value shall be reduced by 10; if

the units'digit flickers press key, the value shall be added with 1，while press key,

reduced 1. Press for choosing the digit of flickering display, when units'digit flickers,

press key，return to display status of parameter number. Continues to press key

by 3s，exit from parameter setting state and save the parameter value.
I. Setting for the number of flywheel teeth
When crank success conditions (P01) select 1 ( Magnetic Pickup + generator
frequency), must set the number of flywheel teeth. If the number of wheel teeth is known,
you may set the number of flywheel according to P03. If unaware of the number of flywheel
teeth, there is automatic test function for choose. You may test and set the number of
flywheel teeth by the steps as follows:
‹ Continues to press key by 3s, enter into parameter setting status.
‹ Press for slecting P02，then press key for displaying the number of
flywheel teeth by auto calculation.
‹ Press key for starting the generator set，then release key immediately
after start.
‹ Use the AC voltage meter to detect the output voltage of magnetic speed sensor，

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 Fujian Fu'an Deppblue Electronic Co.,Ltd. User's manual for GAC608 controller
generally, it should be in the range of 3V~30V, if not, adjust the clearance
between the magnetic speed sensor and flywheel.
‹ If the generator set is working normally, the nixietube can display the number of
flywheel teeth by auto calculation.
‹ When the number display is stable, press key，then press key，the number
shall flickers, this means the number of flywheel teeth is effective and saved into
P03.
‹ Continues to press key by 3s, the system shall quit from parameter setting
state and save the parameters.
6、Typical Application
The typical diagram for GAC608 is shown as follows:

Load U V W N
ATS
U U
Generator

Utility
V
W W
N N

9 10 13 14 16 15 12 11

GAC608
2 1 21 24 23 22 20 19 18 17 6 7 8 3 4 5
Battery-

Raise Speed Relay

Drop Speed Relay

Emer. Stop

Crank Relay

Water Temperature Sensor

Heat Relay

Oil Temperature Sensor

Stop Relay

Oil Pressure Sensor

Battery+

K5 K2
Fuel Valve
Stop solenoid

Alarm
Speed Sensor

K1 K1 K2 K3 K4 K5
Crank Motor
Heater

Meter Power

7、Installation
The controller is designed to panel installation mode , and it is fixed by clamps when it is
installed. The overall dimension and panel tapping dimension are given as follows:

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 Fujian Fu'an Deppblue Electronic Co.,Ltd. User's manual for GAC608 controller

8、Test run
Before operation, inspections that are recommended as follows should be carried out:
a. Check and assure that all connections are correct , and that diameter of wire is
suitable ;
b. The DC power supply of controller is equipped with fuse ,and the positive
supply (+Ve) and the negative supply (-Ve) connected with battery are connected
correctly ;
c. The emergency stop input is connected with the positive supply (+Ve) of the
battery though the NC terminal and fuse of emergency stop button.
d. The suitable operation should be taken to prevent the engine from crank
success (such as dismantling the connection of crank motor),check and assure that it
is correct , then connect with battery ,select manual mode ,the controller will execute
program .

e. Press down start button ，the generator set will crank , after starts have been
carried out according to setting crank numbers ,the controller sends the signal that

indicates crank failure ; Press key to make the controller resetting ;

f. Restore the measure that prevents the generator set from crank success( such

as restoring the connection of crank motor ); Press start button again ，the
generator set will crank , if crank is normal , the generator set will operate from idle
state (if idle has been set ) to normal state . In the meantime，observe the running
condition of engine as well as voltage and frequency of AC generator. If there is
abnormal , stop the generator set ,then check connections of each part according to
this hand book ;
g. Choose auto state thought the front panel，then turn on the main power ,the
controller switches over ATS (if it exist) to mains on load after pass through the main
power normal delay , after cooling time , and then shut down to go into standby state
until the main power is abnormal again;
h. After the main power is abnormal again, the generator set will crank into normal
running state, and then switch the ATS to generator set on load. If not, you may check
the connections of ATS according to this hand book；
f. For more information, please contact our technicists in time.

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 Fujian Fu'an Deppblue Electronic Co.,Ltd. User's manual for GAC608 controller

9、Troubleshooting

Fault Symptom Possible measures

The controller is not work
Generator set stop
Controller emergency stop
Lower oil pressure alarm after Check the oil pressure sensor input and its connection
crank success
High water temperature
alarm after crank success
Failure to crank
1.Check the battery
2.Check the connection of controller
3.Check the DC fuse
1.Check if the water temperature is over high
2.Check the voltage of generator
3.Check DC fuse
1.Check if the emergency button is normal
2. Check if the positive pole of battery has been connected
to emergency stop button correctly
3.Check if there is opening or short in connection
Check the water temperature sensor input and its
connection
1. Check the actuator and its connection
2. Check fuel
3. Check the battery voltage
4. Check magnetic and its connection

Fujian Fu'an Deepblue Electronic Co.,Ltd.

ADD：No.95,Yangquan Road, Fu’an City, Fujian http://www.smartcon.cn
TEL：0593-2119335 http://www.smartcon.net.cn
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