GENERAC 5464 21 Light Surface Mount Remote Annunciator Panel with 8 Relays HTS Owner’s Manual

GENERAC 5464 21 Light Surface Mount Remote Annunciator Panel with 8

Relays HTS

ANNUNCIATOR DESCRIPTION

The remote annunciator is available in the following versions:

•  0G5719 – Remote Annunciator has both relays and LEDs/Keypad (RRP & RAP)
•  0G5720 – RRP version – Remote Relay Panel (Relays with no LEDs/Keypad)
•  0G5721 – RAP version – Remote Annunciator Panel (LED’s/Keypad without relays J1 – J8)

The Remote Annunciator provides remote monitoring and annunciation of up to 18 generator parameters using the lights/LEDs located on the annunciator keypad. Selected generator parameters can be annunciated using the eight Form A relays provided on 0G5719 and 0G5720.

The Remote Annunciator also provides two system-level warn-ings which are System Ready and Communications OK. Multiple annunciators can also be connected to obtain remote monitor-ing and annunciation of all 18 generator parameters. Power to the remote annunciator is supplied from the generator battery (+ 12VDC or + 24VDC).

Communication with the Remote Annunciator is via an RS485 serial data link. The remote annunciator is typically configured for listen-only mode (also called slave or passive mode). In this operat-ing mode, the annunciator receives information on the generator status, from the generator controller and activates/deactivates the relay outputs to reflect the status of up to eight selected generator parameters. The remote annunciator can also be configured to request status information from the generator (called master or active mode).

The specific faults to be annunciated using the relay outputs (J1 – J8) can be selected using either the DIP switches located on the annunciator printed circuit board, or the Graphical User Interface (GUI) available using a computer via the RS232 connector on the annunciator printed circuit board (see Figure 2). Relays J1 – J8 provides a set of normally open contacts. All relays are energized (contacts closed) when power is applied to the annunciator. The relay selected to annunciate a particular fault will then open during a fault.

The terminal block connections (J10), used to connect the battery supply and the RS485 communication lines to the remote annun-ciator are shown in Figure

1. The location of DIP switches S1, S2, S3 and S4 and the RS232 connector are shown in Figure 2.

DETAILED SPECIFICATIONS

ENVIRONMENTAL SPECIFICATIONS

Operating Temperature – 25°C (-13°F) to + 60°C (140°F) Humidity 0 to 95% Non Condensing

POWER SUPPLY REQUIREMENTS

• Power Supply Source: Generator Battery to comply with NFPA
• Power Supply Voltage: + 12 or + 24VDC (Annunciator operating range is 6V to 30VDC
• Power UsagE: 6 Watts (typical when all the relays and keypad are energized)
• Power Supply Cable: 2 wire – Voltage drop across each conductor must be less that 1V.

COMMUNICATION WITH GENERATOR CONTROL SYSTEM

• Communication Link: 2 wire RS485 fully isolated.
• Communication Cable: 2 wire RS485 — twisted-pair with overall shield/screen (i.e. Belden 3105A).
• Maximum Cable: Length 4,000 feet
• Baud rate Auto-detect: at 57.6K, 38.4K, 9600 or 4800 (no parity,

NOTE:

1.  The RS485 cable should not be run in the same conduit, or in the same wire grouping as any high voltage or high current conductors.
2.  The generator control panel Baud Rate should be selected to be compatible with other components that are connected to the RS485 communication line.

RELAY OUTPUTS (J1-J8) – 0G5719 & 0G5720 ONLY

• Contact per Channel One Normally Open contact. Energized when annunciator is powered and no faults are present.
• Maximum contact rating: 30VDC/1A

ALARM RELAY OUTPUT (J9)

• Contact Type SPDT (N.O. & N.C. contacts) Energized when annunciator is powered and no faults are present.
• Maximum contact rating: 30VDC/1A

TRANSPORTATION AND STORAGE

Temperature: 30°C (-22°F) to + 80°C (176°F) Humidity 0 to 95% Non Condensing

INSTALLATION AND MOUNTING

1. F or ALL models installation must always comply with applicable codes, standards, laws, and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, the generator and related components must be installed completely in conformance with the manufacturer’s instruc-tions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in non-compliance with such codes, standards, laws and regulations.
2.  The plastic knockout that is used to route the wires and cables into the annunciator should be removed with the annunciator firmly supported by placing it on a flat surface.
3.  q Wire tie-downs are provided in two places on the base of the annunciator to provide strain-relief for the connecting cables and wires (Figure 3).

RELAY ANNUNCIATION (J1 – J8)
The user can select up to eight of the following 18 generator parameters to annunciate via the relays when the 10 positions (S1) and the 8 positions (S2) DIP switches on the annunciator PCB are being used.

Relay outputs J1 through J8 are assigned to the selected param-eters in sequential order. For example, if DIP1 – 1 through 8 are selected, these faults are assigned to relays 1 through 8 respec-tively as shown in Figures 4 and 5.

Figure 4 — DIP Switch S1 Settings

Figure 5 — DIP Switch S2 Settings

NOTE:
If a unit is wired up and then subsequently an additional DIP switch position is selected or deselected, all the relay outputs are re-assigned sequentially and therefore the annunciator terminals may require re-wiring.

PARAMETER SELECTION EXAMPLES

Example 1
DIP S1-1, 3, 5, 10 are initially selected, these are assigned to relays 1, 2, 3, 4 (Figures 6 and 7).

Figure 6 — S1

Figure 7 — S2

Example 2
If subsequently DIP1-3 is removed, and DIP2-5 is added, then relays will be re-assigned (Figures 8 and 9).

Figure 8 — S1

PARAMETERS S1.1 – S1.10 & S2.1 – S2.3
When a remote annunciator (0G5719) or Remote Relay Panel (0G5720) is used in a Modular Power System (MPS), an alarm on any one of the generators causes the associated relay to activate.

PARAMETER “GENERATOR RUN”
This parameter is defined as any one or more generators in the system running.

PARAMETER “GENERATOR POWER”
This light/LED indicates different things depending on the type of system it is attached to.

•  It is defined as whether the Transfer Switch is in the Generator Supply Position.
•  For a PowerManager System Controller (PM-SC with external transfer switch(es)), generator power is defined as anyone or more generators in the system running and connected to the generator bus.
•  For a non-paralleling engine controller (PM-GC WITHOUT internal transfer switch), it represents the status of input 4 (TB2-5) to the generator controller. This should be connected to the generator side auxiliary contact of the external transfer switch. A closure to the ground will cause the light to illuminate. This shows whether the load is powered by the generator.
•  For an engine controller that is part of an MPS system, generator power represents the state of the internal contactor that the generator is connected to.

PARAMETER “LINE POWER”
This light/LED indicates different things depending on the type of system it is attached to.

•  Is defined as whether the Transfer Switch is in the Utility Supply Position.
•  For a Power Manager System Controller (PM-SC with external transfer switch(es)), line power represents the auxiliary input C (TB6-4).
•  For a non-paralleling engine controller (PM-GC WITHOUT inter-nal transfer switch), it represents the status of input 3 (TB2-4) to the generator controller. This should be connected to the utility side auxiliary contact of the external transfer switch. A closure to ground will cause the light to turn ON. This shows whether the load is power by the utility.
•  For an engine controller that is part of an MPS system, line power is not used.

PARAMETER “BATTERY CHARGER AC FAILURE”
This light/LED annunciates upon loss of 120VAC power supply to the battery charger and is communicated to the Annunciator by the generator controller.

GENERATOR STOP INDICATORS

These lights/LEDs will flash when any alarm occurs and the horn will sound as follows:

NOTE:
Both the High Water Temp and the Low Water Level LEDs will turn ON if either fault condition is present. The “Re-arm Horn” switch can be used to turn off and re-arm the horn, or the alarms can be fully acknowledged using the “Reset” switch. The “Reset” switch will turn off and re-arm the horn, and any flash-ing lights will switch to the ON state until the alarms are no longer present at the generator control panel.

NOTE:

•  The alarm condition must be reset at the generator control panel.
•  When this annunciator is used in a Modular Power System (MPS), an alarm on any one of the generators will cause the lights/LEDs to light, and alarms to sound.

WARNING INDICATORS
These lights/LEDs will flash when any alarm occurs and the horn will sound according to the following table:

Annunciator Light| Light Color| Audible Alarm| Latched
---|---|---|---
Pre-low Oil Pressure| Yellow| Yes| Yes
Pre-high Water Temp| Yellow| Yes| Yes
Pre-low Water Temp| Yellow| Yes| Yes
Pre-low Fuel| Yellow| Yes| Yes
Battery Charger AC Failure| Yellow| Yes| No
Low Battery Voltage| Yellow| Yes| No
High Battery Voltage| Yellow| No| No
Generator Run| Yellow| No| No
Generator Power| Yellow| No| No
Not in Auto| Red| Yes| No

These alarms will be latched/not latched by the annunciator according to the above table. They can be acknowledged at the annunciator using the ‘Reset’ switch— the active lamps will then stop flashing and remain in the ON state until the alarm signal clears from the generator control panel. The “Reset” switch will also turn off and re-arm the horn.

NOTE:

•  These lights can only be fully reset when the alarm state is no longer active and “Reset” has been pressed at both the generator control panel and the remote annunciator. Alternatively, at any time the horn can be turned OFF and re-armed with the “Re-Arm Horn” switch.
•  When this annunciator is used in a Modular Power System (MPS), a warning on any one of the generators will cause the above lights to light, and alarm to sound (if the warning is audible).

SPARE INDICATOR

The spare indicator light/LED can be activated from the PM-GC or PM-SC by using the Integrated Logic Controller (ILC) feature in the G-panel or H-panel. Also see the section in this manual describing the operation and set-up of the spare keypad switch.

SYSTEM STATUS INDICATORS
These lights/LEDs are for Status indication only— the normal condition is ON.

SYSTEM READY
The System Ready is defined as ALL “in service” generators are ready to start, run, and supply power. Any generators manually declared as “out of service” will not affect this LED.
Upon a loss of System Ready, the annunciator will respond as follows:

1.  The System Ready LED will begin to flash.
2.  The alarm will sound. The “Re-arm Horn” switch can be used to turn off and re-arm the horn, or the alarm can be fully acknowledged using the reset switch at which time the System Ready LED will turn off and remain off until the System Ready status is returned.

COMMUNICATION OK:
This LED will be ON as long as there is proper communication between the Remote Annunciator Panel and the Generator control system. It typically requires less than a minute for the Annunciator to determine the correct baud rate and connect to the RS485 bus. When communication failure occurs, the Annunciator will flash the communication LED, and sound the horn. The rate of flashing will be indicative of the cause of error.

1.  No reply from the generator control system, Frequency = one second ON/one second OFF
2. Consecutive data errors, Frequency = 0.5 second ON/two seconds OFF.

This alarm condition can be acknowledged at the Annunciator using the “reset” switch – the horn will be turned off and re-armed, and the communication OK light will continue to flash until proper communication returns.

GREEN STATUS LED (INTERNAL TO UNIT)

•  If the green LED is flashing at a one-second on and one-second off rate, the unit is operational and is configured from the Windows Graphical User Interface.
•  If the green LED is flashing at a one-second off and five seconds on rate, the unit is operational and is configured from the DIP switches.
•  If the green LED is flashing at a half-second on and five seconds off rate, the unit is operational but there are no RS485 communications.
•  If the unit is powered for 30 seconds and the Green Status LED does not turn on at all during this time, the circuit board is not functional.

SYSTEM KEYPAD SWITCHES

TEST SWITCH
While the test switch is pressed, all lights/LEDs will light and the horn will sound. When released the lights/LEDs will return to their original status. During this test, communication to the generator control system will be suspended.

RE-ARM HORN SWITCH
The re-arm horn switch will silence the alarm horn and re-arm it for new alarm occurrences.

RESET SWITCH
The reset switch is used to acknowledge any active alarms. It will re-set any flashing light/LED’s to a ON (steady) condition (or OFF for normally on lights). If the alarm no longer exists and it has also been latched OFF at the generator control panel (pre-alarm indicators only) the active light will go OFF. It will also silence the horn and re-arm it for new occurrences.

NOTE:
Pre-alarm conditions MUST be reset at the generator set control panel.

SPARE KEYPAD SWITCH
When DIP Switch S3, Position 4, is in the ON position, it allows the SPARE Keypad Switch to control Relay 8. When this DIP switch is in the ON position, pushing the SPARE keypad Switch will energize Relay 8 and turn on the spare light/LED on the keypad. Pushing the SPARE keypad Switch again will de- energize Relay 8 and turn off the spare light/LED.

NOTE:
The Remote Start capability using the Spare Keypad Switch and Relay 8 is only available when Remote Annunciator version P/N 0G5719 is used.

OTHER FUNCTIONS

GRAPHICAL USER INTERFACE (GUI) OR DIP

SWITCHES ENABLED – DIP SWITCH S3-1
When Position 1 is in the ON position the Graphical User Interface (GUI) must be used to set the relay fault conditions. When Position 1 is in the OFF position the DIP switches on the Annunciator control board must be used to set the relay fault conditions.

MASTER/SLAVE MODE – DIP SWITCH S3-3
Position 3 is used to configure the Annunciator as either a Slave (OFF position) or as a Master (ON position). In Slave mode, it is a Modbus slave and must be connected to a master port on the PM-GC or PM-SC. This method allows for the connection of more than one Annunciator. In Master mode, the Annunciator is the Modbus master and will request data from the PM-GC or PM- SC. The PM-GC or PM-SC must be set as a slave port when the Annunciator is configured as the Master (Figures 10 and 11).

Figure 10 — Annunciators connected to an
H-panel or G-panel Engine Controller

Figure 11 — Annunciator’s connected to a System Controller (SC) and Multiple G-panels

SPARE KEYPAD SWITCH – DIP SWITCH S3-
Position 4, when it is in the ON position, it allows the SPARE Keypad Switch to control Relay 8. When this DIP switch is in the ON position, pushing the SPARE keypad Switch will energize Relay 8 and turn on the spare LED on the keypad. Pushing the SPARE keypad Switch again will de-energize Relay 8 and turn off the SPARE LED. This feature can be used to implement a Remote Start function. This Remote Start feature is only available with the Remote Annunciator version (0G5719) that has both the Relays and the Keypad.

BAUD RATE SELECTION (DIP SWITCH S4)
DIP Switch S4 can be used to set the Communications Baud Rate to a pre- determined value (see table).

ALARM RELAY (J9)
The Annunciator provides a relay with both a Normally Open con-tact and a Normally Closed contact. This relay is energized when DC power is provided to the Annunciator so that in the event power to the Annunciator fails the relay contacts will change state. When the Audible alarm is activated this relay will be de-energized.

RS485 LINE TERMINATION RESISTOR
A 1000 ohm RS485 terminating resistor is installed on the Remote Annunciator PC board via a 3-position jumper (JMP1 in Figure 2). In most applications, this 1000 ohm terminating resistor is connected and the jumper (JMP1) is in the closed or 1-2 position. This jumper can also be moved to the open or 2-3 position

GRAPHICAL USER INTERFACE (GUI)
A DB9 connector is provided on the Annunciator Control Board for use in setting the Annunciator functions. A GenBank serial cable (P/N 0F7707) should be used to connect a laptop computer’s RS232 serial port to the Annunciator DB9 connector. The GenBank cable is a Null-Modem style serial cable with female-to-female DB9 connectors.

Shown in Figure 12 is a typical Windows GUI interface as it appears on the computer display.

RS485 COMMUNICATIONS
In a typical application, the Annunciator monitors (i.e. slave mode) the Generator control system via the RS485 communication line.

SERIAL INTERFACE

Baud Rate: Auto-Detect 57.6K, 38.4K, 9600 or 4800 (No Parity, 2 Stop Bits)

COMMUNICATIONS CONNECT TIME
When an Annunciator is powered up onto an existing RS485 network, there will be a period of time, during which the unit may report a “communication failure”. During this time the Annunciator is searching for the correct Baud rate. The Annunciator will typi-cally communicate within one minute after being connected.

Figure 12 — Annunciator GUI Interface Display

ERROR HANDLING:
An error will be reported by flashing the Communication OK light—the rate of flashing will be indicative of the cause of the error.

1.  No reply from generator control system— frequency one second on/one second off.
2.  Consecutive data errors— frequency 0.5 seconds on/two seconds off.

The Annunciator, if configured for auto-baud rate detect, will try several times at each of four different baud rates (57.6K, 38.4K, 9600 and 4800) before reporting a communication error by de-energizing all the relays and then flashing the Communication OK light.

LIMITS OF OPERATION
The following communication restrictions apply for multiple units on a common RS485 line:

• A maximum of 15, 1000 ohm RS485 Loads (i.e. 57.6K Annunciator, G-panel, H-panels, etc) can be connected to the RS485 bus at one time.

NOTE:
There MUST be only ONE (1) master in the RS485 communication bus. All others must be slaves (PASSIVE).

TERMINOLOGY & ABBREVIATIONS

• GUI: Graphical User Interface for Windows-based computers
• MPS: Modular Power System
• PM-GC: Power Manager – Generator Controller (controls a single Generator)
• PM-SC: Power Manager – System Controller (used to control multiple Generators)
• LEDs: – Light Emitting Diodes
• GenBank: Generator communication system
• ILC: Integrated Logic Controller
• RRP: Remote Relay Panel (Relays with no LEDs/Keypad), 0G5720\
• RAP:  Remote Annunciator Panel (LEDs/Keypad without Relays J1 – J8), 0G5721

TROUBLESHOOTING GUIDE

No Lights/LEDs are Lit.| 1.    Check for the proper battery supply at terminal block J10 pins 1 and 2.

•      J10 pin 1 should be + Battery (12 or 24 volts).

•      J10 pin 2 should be – Battery.

•      Refer to the “ power supply requirements” section at the beginning of the manual for cable specifications.

---|---
|
The “ Communication OK” LED is flash- ing at the rate: second ON/one second OFF.| 1. Does the RS485 communications cable meet specifications. Refer to the “ Communication

with generator control system” section at the beginning of this manual.

2.    Check that the RS485 connections are connected properly.

•      RS485+ connected to J10 pin 5.

•      RS485– connected to J10 pin 6.

•      Is the Shield/screen connected correctly. The shield/ screen should be connected at the Generator end only.

3. Check for proper installation of the RS485 cable between the Annunciator and the genera- tor’s control panel. Is this cable sharing a conduit or running next to any high voltage or

high current electrical lines?

4. Use the Generator Controller GenLink communication diagnostics to check if data is being sent or received via the Tx and Rx check boxes. Go to the pull- down menu for diagnostics and select “ Com Ports” . Select the port the Annunciator is connected to (normally port

0. and look to see if the check boxes change state. If not, data is not being transmitted/ received, check the cabling. If data is being received, check the baud rate settings of all

connected equipment.

|
The “ Communication OK” LED is flash- ing at the rate: 0.5 seconds ON/two seconds OFF.| 1. Does the RS485 communications cable meet specifications? Refer to the “ Communication

with generator control system” section at the beginning of this manual.

2. Is the cable shield connected correctly? The shield/ screen should be connected at the

Generator end only.

3. Check for proper installation of the RS485 cable between the Annunciator and the genera- tor’s control panel. Is this cable sharing a conduit or running next to any high voltage or

high current electrical lines?

4. Use Generator Controller GenLink communication diagnostics to check if data is being sent or received via the Tx and Rx check boxes. Go to the pull- down menu for diagnostics and select “ Com Ports” . Select the port the Annunciator is connected to (normally port 0) and look to see if the check boxes change state. If not, data is not being transmitted/received, check the cabling. If data is being received, check the baud rate settings of all connected

equipment.

The “Green Status LED” (internal to the unit) is flashing at a 0.5 second ON/5

second OFF rate.

| 1. The RS485 Communications is not functioning. See items 1-4 above.

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