Genset Controller Unit And Method For Integrated Handling Of Multiple Gensets With Different Operational Requirements

FORM 2 THE PATENTS ACT, 1970 (39 of 1970) AND THE PATENTS RULES, 2003 COMPLETE SPECIFICATION (See section 10; rule 13) TITLE OF THE INVENTION “GENSET CONTROLLER UNIT AND METHOD FOR INTEGRATED HANDLING OF MULTIPLE GENSETS WITH DIFFERENT OPERATIONAL REQUIREMENTS” APPLICANT KIRLOSKAR OIL ENGINES LIMITED of Laxmanrao Kirloskar Road, Khadki, Pune-411003, Maharashtra, India; Nationality: India The following specification particularly describes the invention and the manner in which it is to be performed 2 GENSET CONTROLLER UNIT AND METHOD FOR INTEGRATED HANDLING OF MULTIPLE GENSETS WITH DIFFERENT OPERATIONAL REQUIREMENTS TECHNICAL FIELD 5

[001] The present invention in general relates controlling of gensets. More specifically, it pertains to a genset controller unit (GCU) and method for integrated handling of multiple gensets with different operational requirements for power generation application. 10 BACKGROUND OF THE INVENTION

[002] Generator sets, often referred to as "gensets", are widely used for power generation application to provide electric power, especially in areas that are far from 15 or not connected to a power grid. The genset typically includes an engine coupled to an alternator. The alternator converts rotational energy from the engine into electrical energy to generate electric power. Such gensets are utilized in many locations where mains supply of electricity is unavailable or as a back-up to mains supply of electricity where supplies are unreliable. The gensets can vary from its 20 different ratings in electrical power output from approx. 5kVA up to around I000kVA.

[003] A genset controller typically controls the operation of the genset, including the operation of the engine and the alternator of the genset. Different types 25 of gensets are used for power applications with various constraints and requirements, and some types of the gensets include, but not limited to, diesel generators (DG), natural gas generators, propane generators, gasoline generators and hybrid generators. Further, these gensets can also be a mechanical type of generator and an electronic type of generator. 30 3

[004] Many gensets are employed with standard configurations and options, but in some circumstances it is also possible to design genset controllers that could control and operate with multiple gensets, including gensets designed and manufactured by different companies with different setting configurations and 5 options. Sometimes the gensets with different power ratings can be replaced with the existing one and multiple gensets with different ratings can also be used for the power applications. In such situation, different genset controllers are in place to handle each of the gensets based on its operation parameters and power ratings. Accordingly, the genset controllers are evolved to improve and automate various 10 control and monitoring capabilities in the power application to meet the requirements of different gensets.

[005] In many instances, different types of genset controllers are used for controlling these different types of gensets to ensure the compatibility in working 15 with the gensets and its components. Also, the genset controllers have to be compatible with different electronic control units (ECU) associated with the gensets. Further, while replacing anyone of the existing genset with different type and power rating of it, still it may require to replace the genset controller as well if such specific genset controller are not previously in place. This can lead to operate multiple genset 20 controllers while using different types of gensets in place, which results in interruption of genset operation due to non-synchronization of multiple gensets and multiple genset controllers, and also results in space utilization to accommodate multiple genset controllers. Thus, it is still a problem and cumbersome in handling the incompatibility between the gensets and the genset controllers of different 25 types.

[006] US6351692B1 discloses a method and apparatus for configuring a genset controller for operation with particular gensets. It specifically defines a genset controller that is configurable for controlling a variety of types of gensets. The genset 30 controller includes a memory for storing a plurality of software routines, a personality profile data set, and a user-settable data set, and further includes a 4 processor coupled to the memory for executing the software routines and reading data from the personality profile data set and the user settable data set to control the genset. The genset controller additionally includes an input port coupled to the memory for enabling changes to the personality profile data set and the user5 settable data set to be downloaded into the memory. The personality profile data set and the user-settable data set include data that configures the genset controller for operation with a particular genset.

[007] US6555929B1 discloses a method and apparatus for controlling a genset 10 having an engine and an alternator in order to prevent an excessive change in a speed of the engine because of a sudden change in a load on the alternator. The method includes obtaining a first measured value of an actual AC output power of the alternator at a genset controller during a first time period, and obtaining a second measured value of the actual AC output power of the alternator at the genset 15 controller during a second time period. The method further includes determining at the genset controller a first output power based upon at least the first measured value, and a second output power based upon at least the second measured value. The method additionally includes determining at the genset controller, based upon the first output power and the second output power, whether the actual AC output 20 power has changed in an amount greater than a first threshold, and providing a first control signal from the genset controller to the genset causing a position of a throttle to be modified when it is determined that the actual AC output power has changed in an amount greater than the first threshold. 25 [008] However, these conventional arts are still not capable of handling of different types of gensets with different power ratings and sources for power generation application, i.e. the conventional arts require different ranges of controllers with different sources to handle different gensets, which is cumbersome and also increases overall costing in genset power applications. Thus, the variety of 30 types and configurations of, and options available on, different gensets has increased such that it is becoming a need to design an improved genset controller with all 5 combined features integrated to get the uniformity in the system. Thus, there is a constant need for the development of advanced controllers which plays a very important role in reliable and intelligent control of a genset system. 5 [009] Therefore, it is desirable to have all possible options, tailored and inhouse genset controller unit that is compatible with various gensets operated with different power ratings, sources, configurations and operational topology, which can address and overcome the above mentioned technical problems and shortcomings of the existing and conventional genset control systems. 10 SUMMARY OF THE INVENTION

[0010] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not 15 an extensive overview of the present invention. It is not intended to identify the key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form as a prelude to a more detailed description of the invention presented later. 20 [0011] An object of the present invention is to provide a genset controller unit (GCU), which is capable of achieving integrated handling of multiple gensets with different operational requirements for power generation application in an efficient, secure and cost effective manner. 25 [0012] Another object of the present invention is to provide a genset controller unit (GCU), which is flexible and compatible with any gensets of different power ratings, sources, configurations and operational topology without increasing overall costing in genset power applications. 30 [0013] Yet another object of the present invention is to provide a genset controller unit (GCU), which facilitates easy connectivity and easy modularity with 6 any gensets for better features and offerings to cover all requirements of customers and genset market.

[0014] Yet another object of the present invention is to provide a method for 5 integrated handling of multiple gensets with different operational requirements for power generation application, which achieves faster analysis and cost effective solution to handle various gensets of different ratings and operating features.

[0015] According to first embodiment of present invention, there is provided a 10 genset controller unit (GCU) for integrated handling of multiple gensets with different operational requirements for power generation application. The GCU comprise a plurality of communication units configured to communicate with a plurality of genset components and a plurality of external devices using different communication protocols. A memory device is configured to store information about 15 a plurality of operating parameters, a plurality of fault parameters and a plurality of user setting parameters in accordance with each genset along with its operational requirements. At least one master unit is communicatively coupled with an engine, an alternator and an electronic control unit (ECU) of each genset through at least one of the communication units for monitoring and controlling the operating 20 parameters of the engine and the alternator of each genset. One or more auxiliary units are configured to monitor and control ON/OFF state of one or more supplementary components of the gensets to maintain preset temperature and supplementary constraint for operation of the gensets. At least one user interface is connected with the master unit and the auxiliary units for acquiring and displaying 25 the operating, fault and user setting parameters and for selecting and activating operating modes of each genset. The master unit and the auxiliary units are interfaced with the gensets through the different communication protocols in such a way that the master unit synchronizes the operational requirements of each of the gensets by monitoring and regulating the operating parameters of each genset, and 30 determines auto mains failure (AMF) by continuously monitoring mains voltage from a mains voltage terminal to automatically start the gensets if mains supply is 7 failed or cut off. Thus, the GCU is capable of achieving integrated handling of multiple gensets with different operational requirements for power generation application in an efficient, secure and cost effective manner. 5 [0016] According to first embodiment of present invention, the master unit synchronizes different types and ratings of the gensets by determining at least the operating parameters of voltage, frequency and phase angle of the gensets. After synchronizing each of the gensets, the master unit operates each genset in a load sharing mode for controlling genset load based on ratings of the gensets, and a load 10 demand mode for controlling genset load based on an external input into the GCU.

[0017] According to first embodiment of present invention, the master unit constantly monitors and determines whether values of the operating parameters of the engine and the alternator of each genset are within a range set for the specific 15 genset. If the master unit determines that the values of the operating parameters of the genset are not within the set range of the genset, the GCU indicates and displays an alert message to the user through the user interface or automatically stops the operation of the genset. If the master unit detects any AMF and/or synchronisation failures from the genset, the GCU indicates and displays an alert message to the user 20 through the user interface or automatically stops the operation of the genset.

[0018] According to first embodiment of present invention, the auxiliary units are communicatively coupled with one or more coolant and oil heaters of the gensets through different sensors to maintain preset temperature of coolant and oil in the 25 gensets and to provide ON/OFF command to the heaters.

[0019] According to first embodiment of present invention, the user interface is designed as a human machine interface (HMI) touch screen display such that the user communicates with the GCU to select and activate at least one of auto/manual 30 operating modes for starting or stopping the operation of the gensets. The HMI touch 8 screen display is configured to display warning messages, alarms and shutdown messages of the gensets.

[0020] According to first embodiment of present invention, the master unit is 5 communicatively coupled to a circuit breaker of each of the gensets any one of the communication protocols to automatically start or stop the operation of the gensets. The master unit is communicatively coupled with an after treatment system controller through one of the communication protocols for deciding and controlling urea dosing in an exhaust system of the gensets. 10

[0021] According to first embodiment of present invention, the GCU is interfaced with a remote monitoring system and a service tool through the communication units via one of the communication protocols. The communication units comprise CAN (Controller Area Network) ports, UART (Universal Asynchronous 15 Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi module, and the communication protocols comprise CAN bus, UART communication, serial communication, MODBUS, Ethernet, GSM (Global System for Mobile Communications) communication. 20 [0022] According to first embodiment of present invention, the operating parameters of the engine and the alternator of the gensets comprise engine voltage, engine current, engine frequency, engine phase angle, engine speed, engine power factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine coolant temperature, alternator voltage, alternator current, alternator frequency, 25 alternator phase angle, and alternator power factor.

[0023] According to second embodiment of present invention, there is provided a method for integrated handling of multiple gensets with different operational requirements for power generation application. The method comprises the steps of: 30 receiving and storing, by a memory device of a genset controller unit (GCU), a plurality of operating parameters, a plurality of fault parameters and a plurality of 9 user setting parameters in accordance with each genset along with its operational requirements through a plurality of communication units, wherein the plurality of communication units is configured to communicate with a plurality of genset components and a plurality of external devices using different communication 5 protocols. The operating parameters of an engine and an alternator of each genset are monitored and controlled by a master unit of the GCU, wherein the master unit is communicatively coupled with the engine, the alternator and an electronic control unit (ECU) of each genset through at least one of the communication units. ON/OFF state of one or more supplementary components of the gensets is monitored and 10 controlled by one or more auxiliary units of the GCU to maintain preset temperature and supplementary constraint for operation of the gensets. The operating parameters of each genset are regulated by the master unit to synchronize the operational requirements of each of the gensets. Auto mains failure (AMF) is determined by continuously monitoring mains voltage from a mains voltage 15 terminal by the master unit to automatically start the gensets if mains supply is failed or cut off. The operating, fault and user setting parameters of the gensets, are displayed on at least one user interface being connected with the master unit and the auxiliary units of the GCU. 20 [0024] According to second embodiment of present invention, the master unit synchronizes different types and ratings of the gensets by determining at least the operating parameters of voltage, frequency and phase angle of the gensets. After synchronizing each of the gensets, each genset is operated by the master unit in a load sharing mode for controlling genset load based on ratings of the gensets, and a 25 load demand mode for controlling genset load based on an external input into the GCU.

[0025] According to second embodiment of present invention, the master unit constantly monitors and determines whether values of the operating parameters of 30 the engine and the alternator of each genset are within a range set for the specific genset. If the values of the operating parameters of the genset are not within the set 10 range of the genset, an alert message is indicated and displayed to the user through the user interface or the operation of the genset is automatically stopped. The master unit detects any AMF and/or synchronisation failures from the genset, and if the AMF and/or synchronisation failures are detected, indicating and displaying an 5 alert message to the user through the user interface or automatically stopping the operation of the genset.

[0026] According to second embodiment of present invention, the auxiliary units are communicatively coupled with one or more coolant and oil heaters of the gensets 10 through different sensors to maintain preset temperature of coolant and oil in the gensets and to provide ON/OFF command to the heaters.

[0027] According to second embodiment of present invention, the user interface is designed as a human machine interface (HMI) touch screen display such that the 15 user communicates with the GCU to select and activate at least one of auto/manual operating modes for starting or stopping the operation of the gensets. The HMI touch screen display is configured to display warning messages, alarms and shutdown messages of the gensets. 20 [0028] According to second embodiment of present invention, the master unit is communicatively coupled to a circuit breaker of each of the gensets any one of the communication protocols to automatically start or stop the operation of the gensets. The master unit is communicatively coupled with an after treatment system controller through one of the communication protocols for deciding and controlling 25 urea dosing in an exhaust system of the gensets.

[0029] According to second embodiment of present invention, the GCU is interfaced with a remote monitoring system and a service tool through the communication units via one of the communication protocols. The communication units comprise 30 CAN (Controller Area Network) ports, UART (Universal Asynchronous Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi 11 module, and the communication protocols comprise CAN bus, UART communication, serial communication, MODBUS, Ethernet, GSM (Global System for Mobile Communications) communication. 5 [0030] According to second embodiment of present invention, the operating parameters of the engine and the alternator of the gensets comprise engine voltage, engine current, engine frequency, engine phase angle, engine speed, engine power factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine coolant temperature, alternator voltage, alternator current, alternator frequency, 10 alternator phase angle, and alternator power factor.

[0031] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments 15 of the invention. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0032] The above and other aspects, features and advantages of the embodiments 20 of the present disclosure will be more apparent in the following description taken in conjunction with the accompanying drawings, in which:

[0033] FIG. 1 illustrates a general diagram of a genset controller unit (GCU) being integrated with multiple gensets, in accordance with one exemplary embodiment of 25 the present invention.

[0034] FIG. 2 illustrates an overall system architecture of an integrated genset controller unit (GCU) interfaced with different types and topology of genset components, in accordance with one exemplary embodiment of the present 30 invention. 12

[0035] FIG. 3 illustrates a high level system architecture of an integrated genset controller unit (GCU), in accordance with one exemplary embodiment of the present invention. 5 [0036] FIG. 4 illustrates a block diagram of an integrated genset controller unit (GCU), in accordance with one exemplary embodiment of the present invention.

[0037] FIG. 5 illustrates a system architecture depicting integration of a genset controller unit (GCU) with an after-treatment system (ATS), in accordance with one 10 exemplary embodiment of the present invention.

[0038] FIG. 6 illustrates a flowchart of a method for integrated handling of multiple gensets with different operational requirements for power generation application, in accordance with another exemplary embodiment of the present invention. 15

[0039] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary 20 embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures. DETAILED DESCRIPTION OF THE INVENTION 25

[0040] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary implementations of the invention. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. 30 13

[0041] Features that are described and/or illustrated with respect to one implementation may be used in the same way or in a similar way in one or more other implementations and/or in combination with or instead of the features of the other implementations. 5

[0042] According to FIG. 1, a general diagram of a genset controller unit (GCU) (100) being integrated with multiple gensets (200) is illustrated in accordance with one exemplary embodiment of the present invention. The present invention describes a genset controller unit (GCU) (100) for integrated handling of multiple 10 gensets (“generator set”) (200) with different operational requirements for power generation application, which is compatible to control variety of gensets of different power ratings, types and topology. This integrated GCU (100) is facilitated with ease of all combined genset features such as auto mains failure (AMF), synchronization, variable power demands (Optiprime functionality), compatibility with different 15 ECUs, and interactive HMI (Human-Machine Interface) display with interactive UI (User Interface) features. The GCU (100) provides a cost effective solution in controlling multiple gensets (200) with different power ratings and different operational topology. 20 [0043] For example, multiple gensets (200) are connected in parallel where some of the gensets are active while others are in standby mode. Also, for example, a network or chain of gensets may generate power together by sharing a load (e.g., by different combinations of the gensets operating together and/or different gensets operating under different operational parameters based on the power output 25 demands). For instance, during continuous operation of the system, the gensets (200), when in parallel operation, may share the load with multiple other gensets in the system. Due to differences in the underlying technology associated with power generation in different types as well as differences in the hardware components and operational topology/configurations of these gensets, the integrated GCU (100) of 30 the present invention is compatible and capable of synchronized controlling different types of these gensets in an integrated and effective manner. It can result 14 in improve efficiency and performance of these gensets for power generation application.

[0044] The system may include multiple gensets (200) with different types and 5 different power ratings used for the power generation application. The genset (200) usually comprises an engine (202) and an alternator (204). The engine (202) can include any type of engine that generates mechanical energy from by consuming a fuel, such as a combustion engine (e.g., diesel engine, gas engine, or other engine that uses a combination of gaseous and liquid fuels) or any other type of engine. In this 10 disclosure, it can be referred as Diesel Genset (DG) in some instances, which is clearly for the purpose of exemplary explanation only, but not by the way of any limitations or restrictions. The mechanical energy from the engine is then transformed into electrical energy by the alternator (204) that is outputted by the alternator as AC power. 15

[0045] According to FIG. 2, an overall system architecture of the integrated genset controller unit (GCU) (100) interfaced with different types and topology of genset components, is illustrated in accordance with one exemplary embodiment of the present invention. The GCU (100) is designed as an integrated, modular and 20 customized controller unit to be in communication with different types of gensets (200) for handling and controlling the operation of multiple gensets in an efficient and synchronized manner. For example, the GCU (100) can be implemented using any combination of hardware components, software components, digital circuitry, and/or analog circuitry wired and/or otherwise configured to perform the functions 25 of the GCU described in the present disclosure. The GCU (100) is integrated with multiple embedded electronics and control architecture related to different types of the gensets (200), which can act as an universal electronic control system for any types of the gensets (200). 30 [0046] The genset controller unit (GCU) (100) is a primary and supervisory control unit for each genset, and handles different functions of the gensets (200). The GCU 15 (100) is integrated with major basic functions of the gensets (200) such as monitoring of genset parameters, controlling genset functions and protection of the gensets. The GCU (100) is interfaced with the engine or mechanical engine system (202) of the gensets (200) using sensors or actuators and with the alternator (204) 5 of the gensets (200), which facilitates monitoring, controlling and protection of the engine (202) and the alternator (204) of the gensets (200).

[0047] The GCU (100) is integrated with additional functions of the gensets (200), i.e. is suitable and capable to handle remote monitoring, genset calibration/service 10 tools and customer BMS (Building Management System) systems in respect of the gensets (200) from multiple manufacturers. The GCU (100) is integrated with userspecific or customized functions of the gensets (200), i.e. is suitable and capable to handle electronic governor, voltage regulations, auto mains failure (AMF) function, synchronization functions, load management and load sharing in accordance with 15 multiple gensets.

[0048] The GCU (100) is interfaced with an external system architecture of the gensets (200), which is interfaced with ECU (Electronic Control Unit) (206), mechanical engine system (202), alternator (204), external customer interface 20 (210) with configurable I/O (input/output), BMS (214), calibration/service tool (208), external server interface (216) and distribution panel (212) of a genset system.

[0049] The GCU (100) comprises at least three CAN ports for communicating with 25 the ECU (206), other GCU for LDSS (Load Dependent Start/Stop) and calibration/service tool (208) for facilitating monitoring, controlling and calibration/diagnostic of the ECU (206), other GCU and calibration/service tool (208). 30 [0050] The GCU (100) comprises at least three UART for Modbus commination with the HMI user interface and BMS system (214)for data communication. The GCU 16 (100) is also composed of an in-build capability or onboard remote monitoring unit to transmit and communicate with a remote monitoring system (RMS) over GSM/CDMM communication with the help of a server interface (216), and a serial communication for USB (Universal Serial Bus) connection for data transmission. The 5 GCU (100) is also interfaced with a distribution panel (212) of the genset system for controlling and feedback operations, and interfaced with the external user connections (210) for monitoring, controlling and feedback operations.

[0051] The present genset controller unit (GCU) (100) is designed with modular 10 combination and configuration to achieve all genset functionalities without compromising data sampling and critical operations of the gensets (200). The GCU (100) provides more flexibility and modularity to cater all kind of genset user, i.e. achieving genset control and monitoring, auto mains failure (AMF) functionality, genset protection and additional input and outputs for customization. 15

[0052] According to FIG. 3, a high level system architecture of the integrated genset controller unit (GCU) (100) is illustrated in accordance with one exemplary embodiment of the present invention. The integrated genset controller unit (GCU) (100) is categorized with different sections based on its operation. The system 20 structure of GCU (100) is designed with different sections or blocks, i.e. hardware & base layer section (302), genset control state section (304), communication section (314), configuration and I/O (Input/Output) block (306g), AMF and sync functionality block (306f), alternator monitor and control section (306e), engine monitor and control section (306d), alternator protection section (306a), engine 25 protection section (306b), AMF or sync protection section (306c), event handler block (308), HMI section (310), and HMI and customer (user) interface (312).

[0053] The hardware & base layer section (302) is a main hardware circuit board of the GCU (100). It comprises all the hardware components, which are driving the 30 peripheral subsystems of the GCU (100). This section (302) is arranged with several components like main microcontroller, DC (Direct Current) power circuit, ADCs 17 (Analog-to-Digital Converter), on-board memory, physical layers of all network communication protocols and peripheral active/passive electronic components. This section (302) also comprises base software codes, where the board initialization occurs. 5

[0054] The genset control state section (304) controls a main state flow of the GCU (100), i.e. controlling the flow from starting till the running state. The genset control state section (304) is also linked to a fault handling section and an event logging section. The peripheral systems send input to the GCU (100), which drives this 10 control state section (304), and subsequently drives the outputs to run the genset system.

[0055] The communication section (314) enables the GCU (100) to communicate with sensors and peripheral sub systems of the gensets (200) over various 15 communication protocols, like CANBUS, UART, CAN, Serial or SPI (Serial Peripheral Interface), MODBUS and Ethernet, which are managed and controlled by this communication section (314). This communication section (314) is also responsible for sending data to the remote monitoring device and service tool over various communication protocols like GSM/CDMM communication. 20

[0056] The configuration and I/O block (306g) defines inputs and outputs of the GCU (100), where there are 2 types of I/Os (analog and digital), which are divided into fixed and configurable input/outputs. This configuration and I/O block (306g) initializes all the I/Os, and latches the configurable I/Os to its dedicated general 25 purpose input/outputs from the microcontroller in the hardware & base layer section (302) of the GCU (100).

[0057] The AMF (Auto Mains Failure) and sync functionality block (306f) is an addon functionality or feature in the GCU (100). This AMF and sync functionality block 30 (306f) can automatically start the genset (200) once mains power supply has been cut off. The AMF and sync functionality block (306f) helps in synchronizing two or 18 more gensets (200) when the need arises, by matching primary parameters like voltage, frequency and phase angle of the gensets (200). Also, these AMF and sync functions can be incorporated into the system on user and system requirements. 5 [0058] The alternator monitor and control section (306e) monitors and controls the alternator related parameters like line voltage, current, frequency, phase angle and power of the alternator (204) of the gensets (200).

[0059] The engine monitor and control section (306d) monitors and controls 10 engine related parameters like engine speed, lube oil pressure, coolant level, battery voltage and coolant temperature of the engine or engine system (202) of the gensets (200).

[0060] The alternator protection section (306a) monitors the alternator 15 parameters and determines whether values of the alternator parameters are within the set range or not. If the values of the alternator parameters are not within the set range, i.e. goes above or below the set range, the GCU (100) indicates and displays a warning message or shutdowns the genset system based on the severity of fault in the values of the alternator parameters. 20

[0061] The engine protection section (306b) monitors the engine parameters and determines whether values of the engine parameters are within the set range or not. If the values of the engine parameters are not within the set range, i.e. goes above or below the set range, the GCU (100) indicates and displays a warning message or 25 shutdowns the genset system based on the severity of fault in the values of the engine parameters.

[0062] The AMF or sync protection section (306c) monitors the AMF and synchronization parameters and determines whether values of the AMF and 30 synchronization parameters are within the set range or not. If the values of the AMF and synchronization parameters are not within the set range, i.e. goes above or 19 below the set range, the GCU (100) indicates and displays a warning message or shutdowns the genset system based on the severity of fault in the values of the AMF and synchronization parameters. 5 [0063] The event handler block (308) manages any faults that occur in the genset system. The faults can be categorized as active and inactive, and warning or shutdown fault. The event handler block (308) is configured to maintain the history of faults in the GCU (100). 10 [0064] The human machine interface (HMI) section (310) is designed of a touch screen display with different dimensions (as per the user requirements) for enabling the user to interactwith the GCU(100) and the genset system. The HMI section (310) can communicate with the GCU (100) and its components over UART communication and with the help of HMI and customer (user) interface (312). The 15 HMI section (310) is configured to perform primary operations and functions like selecting operating modes (auto mode and manual mode) as well as starting and stopping of the genset in manual mode.

[0065] According to FIG. 4, a block diagram of the integrated genset controller unit 20 (GCU) (100) is illustrated in accordance with one exemplary embodiment of the present invention. The integrated genset controller unit (GCU) (100) primarily comprises a master unit (402), one or more auxiliary units (404), an user interface (406), a plurality of communication units (408) and a memory device (410). The master unit (402) can also be referred as master card or base card or master 25 circuitry board, and similarly, the auxiliary units (404) can also be referred as auxiliary cards or auxiliary circuitry boards. The user interface (406) is designed as Human Machine Interface (HMI) display with different sizes like 5 Inch display, 7 Inch display and 10 Inch display. With the combination of these components, the GCU(100) provides cost effective solutions to achieve all the flexibility requirements 30 of the genset user and the genset market. 20

[0066] The communication units (408) are communicatively connected to the master unit (402) and the auxiliary units (404) in such a way that the communication units (408) can facilitate the master unit (402) and the auxiliary units (404) to communicate and understand any genset functions and parameters 5 irrespective of its types. The communication units (408) are configured to communicate with a plurality of genset components and a plurality of external devices and peripheral systems using various different communication protocols, which enables the GCU (100) to communicate with any network topology. The different communication protocols include, but not limited to, CAN (Controller Area 10 Network) bus for communication with the ECU, UART (Universal Asynchronous Receiver/Transmitter) for communicating with the HMI user interface (406), GSM (Global System for Mobile Communications) Wi-Fi module for wireless communication, as well as MODBUS for communicating with a remote monitoring system. The communication units (408) also include sensors and actuators to enable 15 communication between the GCU (100) and the mechanical engine system (202) of the gensets (200).

[0067] The memory device (410) is arranged in the GCU (100) to store information about several operating parameters, several fault parameters and several user 20 setting parameters in accordance with various types of gensets (200) in the genset market. The memory device (410) is communicatively coupled with the master unit (402) and the auxiliary units (404), where the memory device (410) includes, but not limited to a random-access memory (RAM), a read-only memory (ROM) and a flash memory. 25

[0068] The master unit (402) in the GCU (100) is configured to handle different ratings and different operational topology of the gensets (200). The master unit (402) is communicatively coupled with the engine or engine system (202) and the alternator (204) of the gensets (200) through any one of the communication units 30 (408) for monitoring and controlling the operating parameters of the engine (202) and the alternator (204) of the gensets (200). The auxiliary units (404) are 21 communicatively coupled with one or more coolant heaters, one or more oil heaters and one or more supplementary components of the gensets (200) for monitoring and controlling ON/OFF state of the coolant heaters, the oil heaters and the supplementary components of the gensets (200) to maintain preset temperature of 5 coolant, oil and supplementary constraint of the gensets (200). The HMI user interface (406) is connected with the master unit (402) and the auxiliary units (404) to enable user to select and activate operating modes (i.e. auto and manual modes) of the gensets (200). 10 [0069] The master unit (402) and the auxiliary units (404) are interfaced with the gensets (200) through the different communication protocols in such a way that the master unit(402) synchronizes operation of each of the gensets (200) by monitoring and regulating the operating parameters of each of the gensets (200), and determines auto mains failure (AMF) to automatically start the gensets (200) even 15 if mains supply is failed or cut off. The master unit (402) synchronises different types of the gensets (200) by matching the operating parameters of voltage, frequency and phase angle of the gensets (200).

[0070] The master unit (402) is configured to constantly monitor and determine 20 whether the operating parameters of the engine (202) and the alternator (204) of the genset (200) are within a range set for the genset. If the master unit (402) determines that the operating parameters of the genset (200) are not within the set range of the genset, the GCU (100) indicates an alert message to the user or automatically stops the operation of the genset (200).If the auto mains failure (AMF) 25 and/or the synchronisation failures are detected by the master unit (402), the GCU (100) indicates an alert message to the user or automatically stops the operation of the genset (200). The master unit (402) is communicatively coupled to a circuit breaker of the gensets (200) to automatically stop the operation of the gensets (200). The master unit (402) of one GCU (100) is also interfaced with other GCU 30 (100) by means of genset load-dependent start and stop (LDSS) parameters. The 22 master unit (402) is also integrated with an after treatment system (500) in the engine or engine system (202) of the gensets (200).

[0071] The master unit (402) is the heart of the genset controller unit(GCU) (100), 5 and handles basic major functions of the genset controller unit (GCU). The basic major functions of the GCU (100) comprises engine control, alternator control, genset operation, auto mains failure, synchronization of two or more gensets, circuit breaker control, integration with after treatment system, communication, customized inputs and outputs, protection system, alarm and shutdown, and genset 10 load-dependent start and stop (LDSS). The master unit (402) is configured with the requirements of all the basic major functions, and is capable to provide faster analysis and response, protection algorithms, easy connectivity with customer system, and easy modularity for better feature offering. 15 Engine Control Function

[0072] The engine control function is an important and critical function of the master unit (402) in the GCU (100), where the GCU (100) plays a supervisory role for controlling the engine (202) of the genset (200). The master unit (402) of the GCU(100)is configured to manage a governing part of the engine (202) of the genset 20 (200). In the governing part of the engine (202), the master unit (402) of the GCU (100) controls the power output of the engine (202) by maintaining set RPM (Revolutions Per Minute) in a steady state condition and a transient condition. The master unit (402) of the GCU (100) is configured and integrated with different governing engine systems such as electronic system of ECU, electromechanical 25 governing system, mechanical governing system and cold starting kit, being used by different types of gensets (200).

[0073] The master unit (402) is integrated with the ECU (206) in such a way that the GCU (100) is communicated with the ECU (206) through a common 30 communication CAN bus protocol of J1939, where with this CAN bus protocol of J1939, the master unit (402) of the GCU (100) can control the engine (202) of the 23 genset (200). The master unit (402) is integrated with the electromechanical governing system in such a way that the GCU (100) is communicated with the electromechanical governing system through different sensors, where an electronic governor is a part of the complicated electromechanical governing system. The 5 master unit (402) enables the GCU (100) to receive feedback from the different sensors and to communicate command signals to the electronic governor for controlling speed of the engine (202) and managing load of the engine (202).

[0074] The master unit (402) is integrated with the mechanical governor in such a 10 way that the GCU (100) is communicated with the mechanical governor through different sensors, which enables the GCU (100) to measure speed and different parameters of the engine (202). The master unit (402) can read all engine parameters, read all engine warnings, alarms and shutdowns as well as maintain engine set speed of the engine (202). The master unit (402) in the GCU (100) is 15 arranged and configured to read different parameters of the engine (202) using different principles based on the configuration of the engine of the different types of gensets (200).

[0075] The master unit (402) is configured to read and control various engine 20 parameters, i.e. operating parameters of the engine (202) of the gensets (200). The primary operating parameters of the engine (202) includes, but are not limited to engine RPM (Revolutions Per Minute), coolant temperature, lube oil pressure, lube oil temperature, intake manifold temperature, exhaust temperature for each cylinder, battery voltage, engine running hours, fuel consumption, and lube oil 25 consumption.

[0076] For example, if the engine (202) is CRDI (Common Rail Direct Injection) associated with the ECU (206), the master unit (402) of the GCU (100) can read all parameters on the J1939 communication protocol, where this type of engine 30 configuration and parameters is available always to the master unit (402) of the GCU (100). For example, if the engine (202) is associated with the electronic governing 24 system, the master unit (402) of the GCU (100) determines the communication protocol available in the electronic governing system to communicate and read partial or available parameters of the engine (202) from the electronic governor for controlling and managing the engine (202) of the genset (200). This type of engine 5 configuration and parameters is available to the master unit (402) of the GCU (100). For example, if the engine (202) is a mechanical engine, the master unit (402) of the GCU (100) is connected directly with one or more sensors to read and control various parameters of the mechanical engine (202) of the gensets (200). Thus, the master unit (402) in the GCU (100) can able to manage and control all the 10 configuration of the engine (202) to handle multiple types of gensets (200) with any ratings.

[0077] The master unit (402) is also configured to read all warnings, alarm and shutdown of the engine (202) in the genset (200) as like similar configuration of 15 reading all the operating parameters from the engine (202). In case of electronic engines (202) in the genset(200), the master unit (402) can determine and evaluate all parameters relating to warnings, alarm and shutdown of the engine (202) via the communication protocol J1939. In case of electronic governor in the genset (200), the master unit (402) can determine and evaluate some parameters relating to 20 warnings, alarm and shutdown of the engine (202) via the communication protocol available in the electronic governor as well as determine and evaluate some parameters relating to warnings, alarm and shutdown of the engine (202) through the sensors directly connected to the GCU (100). In case of mechanical engine (202) in the genset (200), the master unit (402) can determine and evaluate all the engine 25 parameters relating to warnings, alarm and shutdown of the engine (202) through the sensors directly connected to the GCU (100). For the electronic governor and the mechanical engine (202), the GCU (100) is capable to create set points for each warning and shutdowns of the engine (202), where the GCU (100) can facilitate the user to alter and reset these set points based on configuration and requirements of 30 the engines (202) in the gensets (200). 25

[0078] Further, the screen of the HMI user interface (406)in the GCU (100) displays the warnings, alarm and shutdown of the engine (202), which enables the GCU (100) to indicate the displaying warning, alarm and shutdown on screen, to the user. In case of any warnings and alarms in the engine (202) of the genset (200), the GCU 5 (100) is configured to activate a common potential free contact based on inputs received by the GCU (100) from any kind of signals. For example, the common potential free contact can be NO (Normally Open) type that can be converted to NC (Normally Closed) when the alarm or warning is active. Similarly, in case of any shutdowns in the engine (202) of the genset (200), the GCU (100) is configured to 10 activate a common potential free contact based on inputs received by the GCU (100) from any kind of signals. For example, the common potential free contact can be NO (Normally Open) type that can be converted to NC (Normally Closed) when the shutdown is active. The HMI user interface (406) in the GCU (100) is provided with a reset button on its screen, which enables the GCU (100) to reset all alarm, warning 15 and shutdown. If alarm, warning and shutdown are active from input side, there is no effect by the reset button, where all alarm, warning and shutdown input can get in healthy condition to reset the alarm, warning or shutdown from the GCU (100).

[0079] The master unit (402) of the GCU (100) is capable to maintain the engine 20 speed by determining and controlling the engine parameters of the genset engine (202). In the genset application, the engine speed is usually decided and fixed at the time of manufacturing, and the engine speed parameter is essential to be maintained at its rating for proper output delivery. The engine speed is linked with various genset parameters like frequency (Hz), voltage and etc. Normally, two type of the 25 engine speed is used for the genset application, i.e. one at engine speed of 1500 RPM and second at engine speed of 1800 RPM. It is also used at engine speed of 3000 RPM on few applications as well.

[0080] During production, the base file of the engine RPM is selected so that the 30 master unit in the GCU (100) ensures the engine to run on the set speed of RPM as set during production. In case of CRDI and electronic engines (202), the ECU (206) 26 controls the engine speed by adjusting a fuelling system of the genset. In order to operate multiple gensets (200) in the synchronisation mode, the master unit (402) of the GCU (100) provides a biasing command signal to the ECU (206) to maintain the speed as per synchronisation requirement. In case of electronic governor 5 engines (202), the master unit (402) of the GCU (100) provides a biasing command signal to the electronic governor to maintain the speed as per synchronisation requirement.

[0081] In case of mechanical engines (202), the master unit (402) of the GCU (100) 10 monitors the speed of the engine (202), and with reference to the monitored engine speed, the master unit (402) of the GCU (100) calculates and displays the frequency of the genset on the HMI screen (406, 310). Some of the correlation of the engine speed and the frequency are 1500 RPM = 50 Hz, so 30 RPM = 1 Hz; 1800 RPM = 60 Hz, so 30 RPM = 1 Hz; 3000 RPM = 50 Hz, so 60 RPM = 1 Hz; and 3000 RPM = 60 Hz, 15 so 50 RPM = 1 Hz. With reference to the correlation of the engine speed and the frequency, the GCU (100) displays the frequency on the HMI screen (406, 310), which can be considered for synchronisation of multiple gensets (200) in operation.

[0082] The auxiliary units (404) of the GCU (100) are integrated and associated 20 with a cold starting kit to supply and operate the genset engine (202) at sub-zero and higher altitude conditions. The auxiliary units (404) of the GCU (100) are configured to control and manage ON / OFF condition of coolant heaters, oil heaters and any other components of the genset (200). In this configuration, the auxiliary units (404) of the GCU (100) maintains a temperature set for the coolant, oil and 25 other system such that the auxiliary units (404) monitor the temperature through different sensors and provide ON / OFF command signals to the heaters to maintain the temperature. Engine Protection Function 30 [0083] The master unit (402) of the GCU (100) is configured to provide engine protection based on application type of the gensets (200). In FAE (Full Authority 27 Engine) mode, the master unit (402) of the GCU (100) communicates with the ECU (206) over the communication protocol J1939 such that the GCU (100) can able to retrieve all Fault Codes (FC) over the communication protocol J1939 for protecting the engine (202) in the genset (200). The list of FC can be supported by the GCU 5 (100) as per communication protocol J1939 standard based on SPN (Suspect Parameter Number) / FMI (Failure Mode Identifier) codes. Whereas, in electro mechanical mode, the master unit (402) of the GCU (100) protects the genset engine (202) based on engine performance input to the master unit (402) of the GCU (100) by checking with threshold values set for the engine (202), which enables the GCU 10 (100) to take decision of warning or shutdown of the gensets (200) based on the severity of the fault. The list of FC needs to be supported by the GCU (100) includes, but not limited to low oil pressure (Warning/Signal), over speed, HCT (High Coolant Temperature), LCT (Low Coolant Temperature), fail to start, fail to crank, low battery, high battery, weak battery and charging failure. 15 Alternator Control Function

[0084] The alternator control function is another important and critical function of the master unit (402) in the GCU (100). The master unit (402) of the GCU (100) is configured and integrated with the alternator (204) to monitor and control the 20 alternator (204) of the genset (200) by measuring and monitoring all alternator parameters, voltage regulation and cold starting kit. The GCU (100) is a major monitoring and controlling unit for the alternator (204) of the genset (200) without the need for any other controller or supervisory module. 25 [0085] The master unit (402) of the GCU (100) directly monitors and controls various operating parameters of the alternator (204) of the genset (200) through its specific inputs connections made in the master unit (402). The various operating parameters of the alternator (204) of the genset (200) includes, but not limited to Voltage (Phase to Phase), Average Voltage (Phase to Phase), Voltage (Phase to 30 Neutral), Average Voltage (Phase to Neutral), Current (Phase to Phase), Average Current, Current (Phase to Neutral), Frequency, Power factor (Per phase), Average 28 Power factor, Active Power kW (Per Phase), Average Active Power kW, Apparent Power kVA (Per Phase), Average Apparent Power kVA, Reactive Power kVAR (Per Phase), Average Reactive Power kVAR, Units Generated kWH, Cumulative Units generated kWH, Excitation Current and Excitation voltage. All the above alternator 5 parameter are more important for user interface point of view, where some parameters can be calibrated and calculated from the other parameters. Alternator Parameter - Voltage

[0086] The master unit (402) of the GCU (100) can directly receive inputs of voltage 10 parameter from the alternator (204), where there are four terminals used in the GCU (100) for voltage inputs. The voltage terminals in the master unit (402) of the GCU (100) are capable to take care of the maximum voltage up to 690 V AC (alternating current), and also internal protection can be provided for surge voltages. The voltage input is usually in Phase to Phase and Phase to neutral can be calculated from Phase 15 to phase voltage. The selectable voltage inputs of 110 V AC (Phase to Phase) Voltage, 63 V AC (Phase to Neutral) Voltage, 415 to 440 V AC (Phase to Phase) Voltage and 240 to 260 V AC (Phase to Neutral) Voltage, can be required in the GCU (100) for voltage display. 20 [0087] In normal conditions, majorly 415 V AC is used but 110 V AC system is used for the HV (High Voltage) system like 3.3 kV, 6.6. KV and 11 kV system. The 110 V AC system can be selected for the 3.3 kV / 6.6 kV or 11 kV system, and all related parameters can be aligned with this voltage inputs. It is required to have at least one selection option in the GCU (100) to set-up page from which single phase or 3 phase 25 system can be selected. If single phase system is selected then only one phase and neutral are connected at the terminal. For example, the genset voltage terminal (GVT) in the GCU (100) is defined as below: · 1 – R Phase · 2 – Y Phase 30 · 3 – B Phase · 4 – Neutral 29 In case of 3 phase system, all terminals are connected and for single phase only terminal 1 and terminal 4 are connected. Alternator Parameter - Current 5 [0088] The master unit (402) of the GCU (100) can directly receive inputs of current parameter from the alternator (204) through its current transformer, where there are six terminals used in the GCU (100) for current inputs. The current display depends on the CT (current transformer) ratio. The terminals on the master unit (402) of the GCU (100) are capable to take current up to 10 Amp and provided with 10 a protection fuse in it. Normally, the followings are input current for the master unit (402) of the GCU (100) which is configured with the primary current of the CT. · 1 Amp[SR1] · 5 Amp The above can be selectable settings in the GCU (100). During normal conditions, 5 15 Amp system is used for the LT (Low Tension) and 1 Amp system is used for the HT (High Tension) system. For example, the genset current terminal (GCT) in the GCU (100) is defined as below: · 1 – S1 – R Phase · 2 – S2 – R Phase 20 · 3 – S1 – Y Phase · 4 – S2 – Y Phase · 5 – S1 – B Phase · 6 – S2 – B Phase With the selection of the 1 Amp or 5 Amp, the input are provided in the setup for 25 rated current of the genset (200). The master unit (402) of the GCU (100) displays the actual current on the display screen of HMI (406, 310) in the GCU (100). For example, if the rated current set point is 1600 Amp and the master unit input is selected to 5 Amp and CT ratio is 320. The displayed current can be varied with this ratio and input current at the master unit (402). If the input current is 3 Amp, the 30 GCU (100) displays the current 3 X 320 = 960 Amp on the HMI screen (406, 310), 30 where the protection and display system for the genset also work with the same inputs. Alternator Parameter - Frequency 5 [0089] The master unit (402) of the GCU (100) is configured to calculate the frequency parameter from the speed of the engine (202) in the genset (200), where this frequency parameter is an important parameter linked with the operation of the genset (200). This frequency parameter is set during the manufacturing, and is provided in two options, i.e. 50 Hz and 60 Hz, where both of these parameters are 10 directly linked with the engine parameter. If the engine RPM is 1500 RPM, the frequency parameter can be 50 Hz. Whereas, if the engine RPM is 1800 RPM, the frequency parameter can be 60 Hz. Alternator Parameter - Power Factor 15 [0090] The master unit (402) of the GCU (100) is configured to monitor the power factor parameter by calculating cosine angle between current and voltage for each phase, where this power factor parameter is another important parameter to monitor and calculate the actual power usage of the genset (200). The power factor parameter is essential to calculate different powers like actual power, apparent 20 power and reactive power in the operation of the genset (200). The power factor parameter is displayed in three stages in the screen (406, 310) of the GCU (100), which are: • If the angle between voltage and current is zero, the power factor parameter is unity, which is displayed as 1 on the HMI screen (406, 310) of the GCU 25 (100). • If the angle between voltage and current is zero to 90 degrees, the power factor parameter is legging, which is displayed with positive sign on the HMI screen (406, 310) of the GCU (100). • If the angle between voltage and current is 90 to 180 degrees, the power 30 factor parameter is leading, which is displayed with negative sign on the HMI screen (406, 310) of the GCU (100). 31 The power factor parameter can be used to calculate actual power and apparent power, i.e. if the power factor is more than 1, it can be shown as negative or leading power factor, whereas if the power factor is less than 1, it can be shown as positive or lagging power factor. 5 Alternator Parameter - Actual Power (kW)

[0091] The master unit (402) of the GCU (100) is configured to measure actual power of the genset directly from the genset (200), which is displayed on the HMI screen. This actual power parameter is also an important parameter for the 10 operation of the genset (200). The actual power parameter is continuously monitored by the master unit (402) of the GCU (100) to perform various controlling and adjustment of the operation of the genset system, i.e. the actual power parameter can be used for protection system and different genset operations. 15 Alternator Parameter - Apparent Power (kVA)

[0092] The genset rating is declared in the apparent power output, and the master unit (402) of the GCU (100) is configured to measure and display apparent power parameter on the HMI screen. The parameters of apparent power and actual power are used to calculate the power factor of the genset system. 20 Alternator Parameter - Reactive Power (kVAR)

[0093] The master unit (402) of the GCU (100) is configured to measure, monitor and display reactive power parameter on the HMI screen, which is essential for an electrical system of the genset. 25 Alternator Parameter - Unit Generated (kWH)

[0094] The master unit (402) of the GCU (100) is configured to continuously monitor and calculate unit or energy generated by the genset (200), as per the production of the genset, based on active power generated by genset (200). This 30 parameter is stored in the memory device (410) in the GCU (100) and is essential for calculating efficiency and fuel consumption of the genset (200). 32 Alternator Parameter - Excitation Current

[0095] The master unit (402) of the GCU (100) is configured to monitor excitation current parameter of the genset (200), which is essential and used for 5 controlling and monitoring the voltage or the voltage output of the alternator (204) in the genset (200) since the excitation current parameter can change the output voltage of the alternator (204). The monitoring and controlling of monitor excitation current parameter is used in trouble shooting requirement to resolve issues or faults in the alternator (204). 10 Alternator Parameter - Excitation Voltage

[0096] The master unit (402) of the GCU (100) is configured to monitor excitation voltage parameter of the genset (200), which is essential and used for controlling and monitoring the voltage or the voltage output of the alternator (204) 15 in the genset (200). Based on the AVR (Automatic Voltage Regulator) system, the master unit (402) of the GCU (100) can able to control either excitation voltage or excitation current for controlling the voltage or the voltage output of the alternator (204) in the genset (200). The master unit (402) of the GCU (100) facilitates the monitoring and controlling of different parameters of the alternator (204) in the 20 genset (200). Alternator Protection Function

[0097] The master unit (402) of the GCU (100) is capable to protect the alternator (204) from any scenario or faults by controlling the parameters of the 25 alternator (204), and also displays the fault as an alarm or warning in the HMI screen (406, 310) of the GCU (100). The essential fault protections provided by the GCU (100) includes, but are not limited to High AC voltage, Low AC voltage, Loss of AC voltage sensing, Over Frequency, Under Frequency, Over Current (Signal/Warning), Current Unbalancing, Over Load (kW based) and Over Excitation. 30 33 Event Handler

[0098] The GCU (100) is arranged with the separate memory device (410) for storing information about various operating parameters as well as various fault 5 parameters in accordance with the genset (200), where the fault parameters comprise active faults and inactive faults. The GCU (100) also indicates the information about these faults on the HMI screen (406, 310).

[0099] Active Fault: When there is any active fault in the GCU (100), the GCU 10 (100) stores it in the location based on warning or shutdown. In active shutdown, the GCU (100) stores the current active shutdown faults, where the faults need to work as FIFO (First In, First Out) manners based on a time stamp. The GCU (100) is capable to store at least 5 numbers of shutdown fault parameters or information in the memory device (410). The fault line information typically includes a fault 15 description (using SNP (Suspect Parameter Number)/FMI (Failure Mode Identifier)), SA (System Action) and engine hour (Hr) information, which are used to pinpoint the cause and nature of a fault. Similarly, in active warning, the GCU (100) stores the current active warning faults, where the faults need to work as FIFO manners based on the time stamp. The GCU (100) is capable to store at least 5 20 numbers of warning fault parameters or information in the memory device (410). The fault line information typically includes a fault description (using SNP/FMI), SA and engine Hr information, which are used to pinpoint the cause and nature of a fault. 25 [00100] Inactive Fault: The GCU (100) stores the inactive faults based on the occurrence and severity in the memory device (410) in FIFO manner. The GCU (100) is capable to store at least 20 fault storing capacity. The fault line information typically includes a fault description (using SNP/FMI), SA, engine Hr, fault severity and occurrence information. 30 34 Genset Operation - Auto Mains Failure (AMF)

[00101] With the current market requirement, all gensets (200) have to meet Auto Mains Failure operational requirement. The GCU (100) is capable to handle the critical operation of Auto Mains Failure (AMF) in the genset application. In this 5 operation, the master unit (402) of the GCU (100) receives inputs of mains voltage R.Y, B and N through MVT (Mains Voltage Terminal), and determines AMF by continuously monitoring the mains voltage through the MVT such that the GCU (100) can initiate start / stop command signals to the genset (200) with respect to status of the mains voltage of the genset (200), which enables automatic start of the 10 genset (200) even if the mains supply is failed or cut off, by triggering motors of the engine (202) of the genset (200) and closing the circuit breaker of the genset (200). The Mains Voltage Terminal (MTV) is defined as: · 1 – R Phase · 2 – Y Phase 15 · 3 – B Phase · 4 – Neutral The GCU (100) issues a start command signal to the engine starting motor based on the conditions that if all 3 phases get failed from mains and/or if one of phase gets failed (single phasing condition) from mains. 20

[00102] With reference to the above condition and inputs, the master unit (402) of the GCU (100) initiates the start command signal to the starting motors of the engine (202) and simultaneously initiates open command to a fuel valve (in case of diesel engine). Accordingly, the genset (200) is operated at the rated RPM and 25 voltage, and the GCU (100) manages the set RPM and voltage of the genset (200) if it is in biasing mode. Then, the GCU (100) (i.e. the master unit (402) of the GCU) is integrated with the circuit breaker of the genset (200) to trigger a close command signal to the genset breaker to feed power to available load connected to the genset (200). 30 35

[00103] The GCU (100) ensures the continuous operation of the genset (200) to feed the power to load until the mains supply gets restored. As soon as the mains supply gets restored, the GCU (100) senses the mains voltage by its continuous monitoring through the MVT, and the GCU (100) first initiates open command 5 signals to the circuit breaker of the genset (200) after expiry of a preset waiting period (for example, waiting for 2 minutes with editable setting). Then, the GCU (100) allows the genset (200) to operate for an extended period of preset minutes (for example, a period of 10 minutes with editable setting), and the GCU (100) initiates close command signal to the fuel valve for stopping the operation of the 10 genset (200) after expiry of the preset extended period. Genset Operation - Engine / Genset starting process

[00104] The master unit (402) of the GCU (100) is capable to handle the critical operation for starting the genset(200). For starting the genset(200), the master unit 15 (402) of the GCU (100) sends a start command signal to start the motor of the genset (200) and simultaneously sends an open command signal to the fuel valve when the utility of mains or grid power supply cuts off. Both the start command and open command signals remain unchanged until the genset engine (202) reaches the operational speed of 180 RPM (set point is editable) or 1 minutes (set point is 20 editable) whichever is earlier, and thereafter, the master unit (402) of the GCU (100) removes the start command signal of the starting motor and retains the open command to the fuel valve.

[00105] If the genset engine (202) does not reach 180 RPM within 1 minute time, 25 the GCU (100) removes both the start and open command signals to the motor and the fuel valve. Thereafter, the GCU (100) waits for 1 Minutes (set point is editable) and initiates a second start command signal to the genset motor. The GCU (100) follows similar steps for the second start command as like the first start command signal. If the genset engine still does not start with the second start command, the 30 GCU (100) waits for 1 Minutes and initiates a third start command signal to the genset motor. The GCU (100) follows similar steps for the third start command as 36 like the first start command signal. If the genset engine (202) does not start even at the third start command signal, the GCU (100) initiates and sends an alarm that the engine (202) is not starting, and also operates the common alarm contact. After the third start command signal, no further start command signal is initiated by the GCU 5 (100) to start the motor and the fuel valve, and simultaneously the GCU (100) sends a close command signal to the fuel valve of the genset engine (202). In Auto Mains failure (AMF) condition, the genset (200) runs in an isolation mode and runs with all the load available in the genset system. 10 Genset Operation – Synchronization

[00106] The master unit (402) of the GCU (100) is capable to handle another critical function of synchronization of the genset operation in the genset system, which is more essential on the genset (200) with different types, sources and loads. For synchronization of the genset operation, the master unit (402) of the GCU (100) 15 monitors and determines at least the parameters of voltage level, frequency and phase angle, before operating or closing the circuit breaker of the genset (200). The master unit (402) of the GCU (100) ensures timing for operating or closing the circuit breaker of the genset (200) when all the parameters of voltage level, frequency and phase angle are matched with different types of gensets (200), 20 different sources and different loads, i.e. synchronization of multiple gensets and synchronization of gensets to mains.

[00107] To ensure better system integration for synchronization, the master unit (402) of the GCU (100) retrieves at least the following inputs from the different 25 sources, i.e. • Voltage input of genset • Voltage input from another source (genset or main grid) • Breaker control of synchronization breaker • Communication lines between multiple gensets (for faster response between 30 multiple gensets) 37 In both the synchronization of multiple gensets and the synchronization of gensets to mains, the master unit (402) of the GCU (100) checks any variation or change in the parameters of voltage level, frequency and phase angle, before operating or closing the circuit breaker of the gensets (200). In the synchronization of gensets to 5 mains, the master unit (402) of the GCU (100) checks any variation or change in the parameters of voltage and frequency level of the mains during the synchronization activity. Whereas, in the synchronization of multiple gensets, the master unit (402) of the GCU (100) checks any variation or change in the parameters of voltage and frequency level of each genset (200) through communication lines being connected 10 with multiple gensets (200) to communicate between multiple gensets, where the communication lines maintain the voltage and frequency for faster response.

[00108] For example, if two or more gensets (200) receive the start command signal at same time, the master unit (402) of the GCU (100) activates the 15 communication lines between multiple gensets (200) to decide at least one master genset from multiple gensets based on the genset that first reaches the set RPM and voltage. Once the first master genset (200) achieves the set RPM and voltage, the mater unit (402) of the GCU (100) actuates to close the first genset breaker in a dead bus mode, and holds the closing of the genset breaker for a moment that all other 20 gensets (200) achieves the set RPM and voltage, i.e. all the gensets (200) are entered into a synchronization mode, and the master unit (402) of the GCU (100) actuates to close all the genset breaker as soon as synchronization conditions are met.

[00109] During the synchronization, the genset (200) is operated in two different 25 operation modes, i.e. load sharing mode and load demand mode. Normally after the synchronization, the gensets (200) are operated in the load sharing mode. In this load sharing mode, the gensets (200) share the available load as per the genset ratings, where it is applicable for both kind operations, i.e. synch with grid and synch with multiple gensets (200). In the load sharing mode, it is important that the 30 gensets (200) share both power like active and reactive power for balancing operation. In order to maintain the power balancing, the GCU (100) maintains the 38 voltage within minimum tolerance using P, I & D (Proportional-Integral-Derivative) algorithm to match the voltage of the genset(200), which helps to balance power on all connected gensets (200). 5 [00110] For example, if the genset (200) is synch with the grid, there is no much control of load managed by the GCU (100) and the GCU (100) has to ensure power availability for the load based on the available load on the genset (200). If multiple gensets (200) with similar ratings are operating in the synchronization mode, the master unit (402) of the GCU (100) monitors and controls load balancing to equally 10 share the load on each of the gensets (200). In case that both the gensets are 100 kVA, and available load is 150 kVA, then the GCU (100) controls both the gensets to run on 75 kVA. If the load is 80 kVA, then the GCU (100) controls both the gensets to run on 40 kVA. 15 [00111] Similarly, if multiple gensets (200) with different ratings are operating in the synchronization mode, the master unit (402) of the GCU (100) monitors and controls load balancing based on percentage of the ratings of each of the gensets (200). 20 [00112] In case that if one genset is 100 kVA, another genset is 200 kVA and available load is 250 kVA, then the GCU (100) controls the 100 kVA genset to run on 83 kVA and controls the 200 kVA genset to run on 166 kVA by sharing and balancing the load with 83% on the ratings of each genset. Thus, the master unit (402) of the GCU (100) facilitates equal percentage of loading on each of the gensets (200) based 25 on its power ratings, which protects the genset (200) with low ratings against overloading by keeping mere equal loading on the gensets (200) without differentiating with its ratings. Load sharing operation: 30 [00113] The master unit (402) of the GCU (100) initiates the start command to both gensets (200) once the mains failure input is received, such that the GCU (100) 39 operates the gensets (200) to run at rated or set RPM and voltage by closing both the genset breakers in dead bus or synchronization mode. Then, the load can be shared on both the gensets (200) and the master unit (402) of the GCU (100) monitors the load on each genset (200). The master unit (402) of the GCU (100) 5 requires set points of Stop in the ranges of 10% to 40% and Start in the range of 60% to 90% for better fuel consumption and operational requirements. The GCU (100) waits initial 10 minutes for the load on each genset (200). If the load on each genset is less than stop set point in the GCU (100), the GCU (100) checks for running hours of the genset (200) and initiates a stop command signal to the genset being operated 10 at higher running hours. In order to stop the genset, the GCU(100) gradually reduces or lowers the load on the genset (200) at higher running hour as per the slop of load reduction. The genset breaker can open at last 5% load on the genset. The genset (200) runs for 5 minutes after opening the genset breaker, and then the genset operation stops after expiry of 5 minutes. If the genset load reaches higher than the 15 start set point, the GCU (100) initiates the start command to the genset, and the genset (200) starts and closes the genset breaker in the synchronization mode. The GCU (100) increases the load on new genset till both loaded as per load sharing values or parameters. If the GCU (100) receives a main restoration input, the GCU (100) is configured to open the genset breaker and transfer the load on the mains 20 supply, and the genset (200) is stopped after running for 10 minutes. Load Demand operation:

[00114] In a load demand mode of operation, the master unit (402) of the GCU (100) is integrated with a load demand mode input to recognize work in a load 25 demand mode of operation, which is a simplest mode of operation. This load demand mode operates with external input like 0 – 5 V DC or 4 – 20 mA input, i.e. 0 VDC or 4 mA can be considered as 0 kVA whereas 5VDC or 20 mA can be considered as highest rating of the genset (200). In this load demand operation, the master unit (402) of the GCU (100) monitors the external input and controls the genset (200) based on 30 the external input. It is not linked with the other genset or mains operation. In order to enable this load demand mode of operation, it is required to have another genset 40 or mains parallel system. If other genset or mains gets failed, the GCU (100) removes the load demand mode and operates the genset (200) in the load sharing mode.

[00115] The GCU (100) handles various operational functions described above 5 with the help of various network communications and protocols. The GCU (100) is arranged with at least three CAN ports for communicating with ECU, Other GCU (for LDSS) and Calibration/service tool. The GCU (100) is arranged with at least three UART ports for Modbus communication with the HMI and BMS system. The GCU (100) is arranged with an in-build capability of remote monitoring and transmits it 10 over GSM/CDMM communication. The GCU (100) is also arranged with a serial communication for USB connection for other data transmission.

[00116] According to FIG. 5, a system architecture depicting integration of a genset controller unit (GCU) (100) with an after-treatment system (ATS) (500), is 15 illustrated in accordance with one exemplary embodiment of the present invention. The genset controller unit (GCU) (100) is integrated with an after-treatment system (ATS) controller (500), i.e. the master unit (402) of the GCU (100) is communicatively coupled with the ATS controller (500) for controlling aftertreatment system application in the engine (202) of the genset (200). The ATS 20 controller (500) receives control inputs from the master unit (402) of the GCU (100) and receives inputs from various peripheral sensor based systems for controlling output of urea dosing in an exhaust system of the genset (200). The ATS controller (500) is communicatively coupled with the GCU (100) and various peripheral sensor based systems with the help of different communication protocols to receive 25 multiple inputs via these different communication protocols.

[00117] The GCU (100) communicates with the ATS controller (500) via CAN bus protocol. Similarly, the ATS controller (500) is connected to an urea quality and DEF (Diesel Exhaust Fluid) level sensor and a Nox (Nitrogen Oxides) sensor via CAN bus 30 protocol. The ATS controller (500) receives CAN inputs from the GCU (100), the urea quality and DEF level sensor and the Nox sensor. The after-treatment system 41 controller (500) is provided with an in-built ADC (Analog to Digital Converter) to receive analog inputs such as ATS (Automatic Transfer Switch) inlet and outlet pressure, ATS inlet and outlet temperature, temperature and manifold absolute pressure, barometric pressure and delta P across DPF (Diesel Particulate Filter) 5 from various peripheral sensor based systems. The ATS controller (500) receives and processes multiple inputs from the GCU (100) and the peripheral sensor based systems to decide and control urea dosing in the exhaust system over high side driving PWM (Pulse Width Modulation) output. 10 [00118] The present invention of integrated genset controller unit (GCU) (100) is a standalone, reliable and intelligent genset controller capable of handling all GCU features combined with additional features such as AMF function, synchronization function, optiprime function, which is compatible with different types and power ratings of multiple gensets (200), is compatible with different ECUs of multiple 15 gensets and facilitates interactive UI features through its interactive HMI display. The GCU (100) is arranged with various general purpose input and output pins, which can receive external parameters as input to respectively drive necessary outputs to carry out all the GCU features combined with additional features such as AMF function, synchronization function, optiprime function. The GCU (100) is capable of 20 handling both analog and digital inputs & outputs. The GCU (100) is capable of communicating to various peripheral systems using different communication protocols, like CANBUS for communication with the ECU, UART for communicating with the HMI screen, GSM Wi-Fi module for wireless communication, as well as MODBUS for communicating with the remote monitoring system. The GCU (100) is 25 also provided with an inbuilt fault detection and handling system. The GCU (100) is also capable of handling start/stop functionality, which can be carried out in both manual method and remote operation.

[00119] According to FIG. 6, a flowchart of a method for integrated handling of 30 multiple gensets (200) with different operational requirements for power generation application, is illustrated in accordance with another exemplary 42 embodiment of the present invention. The method is implemented in the genset controller unit (GCU) (100) for integrated handling of multiple gensets (200) with different operational requirements for power generation application. The GCU (100) comprises a master unit (402), one or more auxiliary units (404), HMI user interface 5 (406), communication units (408) and memory device (410), where the master unit (402) is capable to perform engine control, alternator control, genset operation with auto mains failure and synchronization of gensets, breaker control, integration with after-treatment systems, communication through various protocols, and customized inputs and outputs. The GCU (100) is capable of handling analog and digital inputs 10 and outputs, supporting communication protocols including CANBUS, UART, GSM, and MODBUS, and providing start/stop functionality in both manual and remote modes. The GCU (100) also provides inbuilt fault detection and handling to ensure genset protection and efficient load management and sharing. 15 [00120] At step 602, the GCU (100) receives and stores, at its memory device (410), various operating parameters, various fault parameters and various user setting parameters in accordance with each genset (200) along with its operational requirements with the help of different communication units (408). The different communication units (408) are configured to communicate with several genset 20 components and several external devices using different communication protocols. The communication units (408) comprise CAN (Controller Area Network) ports, UART (Universal Asynchronous Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi module, and the communication protocols comprise CAN bus, UART communication, serial communication, MODBUS, Ethernet, GSM 25 (Global System for Mobile Communications) communication. The GCU (100) is also interfaced with a remote monitoring system and a service tool through the communication units (408) via one of the communication protocols.

[00121] At step 604, the operating parameters of an engine (202) and an 30 alternator (204) of each genset (200) are monitored and controlled by the master unit (402) of the GCU (100). The master unit (402) is communicatively coupled with 43 the engine (202), the alternator (204) and an electronic control unit (ECU) (206) of each genset (200) through at least one of the communication units (408). At step 606, ON/OFF state of one or more supplementary components of the gensets (200) is monitored and controlled by the auxiliary units (404) of the GCU (100) to maintain 5 preset temperature and supplementary constraint for operation of the gensets (100). The auxiliary units (404) are communicatively coupled with one or more coolant and oil heaters of the gensets (200) through different sensors to maintain preset temperature of coolant and oil in the gensets (200) and to provide ON/OFF command to the heaters. 10

[00122] At step 608, the operating parameters of each genset (200) are regulated by the master unit (402) to synchronize the operational requirements of each of the gensets (200). The master unit (402) and the auxiliary units (404) are interfaced with the gensets (200) through the different communication protocols to obtain 15 various information from the gensets (200) for monitoring and controlling the gensets (200). The operating parameters of the engine (202) and the alternator (204) of the gensets (200) comprise engine voltage, engine current, engine frequency, engine phase angle, engine speed, engine power factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine coolant temperature, 20 alternator voltage, alternator current, alternator frequency, alternator phase angle, and alternator power factor. The master unit (402) synchronizes different types and ratings of the gensets (200) by determining at least the operating parameters of voltage, frequency and phase angle of the gensets (200). After synchronizing each of the gensets (200), each genset (200) is operated by the master unit (402) in a load 25 sharing mode for controlling genset load based on ratings of the gensets (200), and a load demand mode for controlling genset load based on an external input into the GCU (100).

[00123] At step 610, auto mains failure (AMF) is determined by continuously 30 monitoring mains voltage from a mains voltage terminal by the master unit (402) to automatically start the gensets (200) if mains supply is failed or cut off. The master 44 unit (402) detects any AMF and/or synchronisation failures from the genset (200), and if the AMF and/or synchronisation failures are detected, indicating and displaying an alert message to the user through the user interface (406) or automatically stopping the operation of the genset (200). 5

[00124] At step 612, the operating, fault and user setting parameters of the gensets (200), are displayed on the user interface (406) being connected with the master unit (402) and the auxiliary units (404) of the GCU (100). The user interface (406) is designed as a human machine interface (HMI) touch screen display (406) 10 such that the user communicates with the GCU (100) to select and activate at least one of auto/manual operating modes for starting or stopping the operation of the gensets (200). The HMI touch screen display (406) is configured to display warning messages, alarms and shutdown messages of the gensets (200). The user interface (406) in the GCU (100) enables the user to select and activate operating modes of 15 each genset (200). The master unit (402) constantly monitors and determines whether values of the operating parameters of the engine (202) and the alternator (204) of each genset (200) are within a range set for the specific genset (200). If the values of the operating parameters of the genset (200) are not within the set range of the genset (200), an alert message is indicated and displayed to the user through 20 the user interface (406) or the operation of the genset (200) is automatically stopped. The master unit (402) is communicatively coupled to a circuit breaker of each of the gensets (200) any one of the communication protocols to automatically start or stop the operation of the gensets (200). The master unit (402) is also communicatively coupled with an after treatment system controller (500) through 25 one of the communication protocols for deciding and controlling urea dosing in an exhaust system of the gensets (200).

[00125] The present invention is capable of achieving integrated handling of multiple gensets with different operational requirements for power generation 30 application in an efficient, secure and cost effective manner, i.e. it achieves faster analysis and provides cost effective solution to handle various gensets of different 45 ratings and operating features. It is flexible and compatible with any gensets of different power ratings, sources, configurations and operational topology without increasing overall costing in genset power applications. It facilitates easy connectivity and easy modularity with any gensets for better features and offerings 5 to cover all requirements of customers and genset market.

[00126] Although the present disclosure has been described in accordance with the embodiments, it is understood that the present disclosure is not limited to the embodiments and structures described above. The present disclosure encompasses 10 various modification examples or variations within the scope of equivalents. Various combinations or forms as well as other combinations or forms including only one element, one or more elements, or one or less elements, fall within the scope of the present disclosure. 15 [00127] Also, it will be appreciated by those skilled in the art that various changes and modifications may be made to the embodiments described herein without departing from the scope of the invention. It is intended that the invention not be limited in any way by the embodiments shown and described herein, but that the invention be limited only by the claims appended hereto. 20 46 WE CLAIM: 1. A genset controller unit (GCU) for integrated handling of multiple gensets with different operational requirements for power generation application, 5 comprising: a plurality of communication units configured to communicate with a plurality of genset components and a plurality of external devices using different communication protocols; a memory device configured to store information about a plurality of 10 operating parameters, a plurality of fault parameters and a plurality of user setting parameters in accordance with each genset along with its operational requirements; at least one master unit communicatively coupled with an engine, an alternator and an electronic control unit (ECU) of each genset through at least one of the communication units for monitoring and controlling the operating parameters 15 of the engine and the alternator of each genset; one or more auxiliary units configured to monitor and control ON/OFF state of one or more supplementary components of the gensets to maintain preset temperature and supplementary constraint for operation of the gensets; and at least one user interface connected with the master unit and the auxiliary 20 units for acquiring and displaying the operating, fault and user setting parameters and for selecting and activating operating modes of each genset, wherein the master unit and the auxiliary units are interfaced with the gensets through the different communication protocols in such a way that the master unit synchronizes the operational requirements of each of the gensets by 25 monitoring and regulating the operating parameters of each genset, and determines auto mains failure (AMF) by continuously monitoring mains voltage from a mains voltage terminal to automatically start the gensets if mains supply is failed or cut off. 2. The GCU as claimed in claim 1, wherein the master unit synchronizes 30 different types and ratings of the gensets by determining at least the operating parameters of voltage, frequency and phase angle of the gensets. 47 3. The GCU as claimed in claims 1 and 2, wherein after synchronizing each of the gensets, the master unit operates each genset in a load sharing mode for controlling genset load based on ratings of the gensets, and a load demand mode for controlling genset load based on an external input into the GCU. 5 4. The GCU as claimed in claims 1 to 3, wherein the master unit constantly monitors and determines whether values of the operating parameters of the engine and the alternator of each genset are within a range set for the specific genset. 10 5. The GCU as claimed in claims 1 and 4, wherein if the master unit determines that the values of the operating parameters of the genset are not within the set range of the genset, the GCU indicates and displays an alert message to the user through the user interface or automatically stops the operation of the genset. 15 6. The GCU as claimed in claim 1, wherein if the master unit detects any AMF and/or synchronisation failures from the genset, the GCU indicates and displays an alert message to the user through the user interface or automatically stops the operation of the genset. 20 7. The GCU as claimed in claim 1, wherein the auxiliary units are communicatively coupled with one or more coolant and oil heaters of the gensets through different sensors to maintain preset temperature of coolant and oil in the gensets and to provide ON/OFF command to the heaters. 25 8. The GCU as claimed in any of the preceding claims, wherein the user interface is designed as a human machine interface (HMI) touch screen display such that the user communicates with the GCU to select and activate at least one of auto/manual operating modes for starting or stopping the operation of the gensets. 48 9. The GCU as claimed in any of the preceding claims, wherein the HMI touch screen display is configured to display warning messages, alarms and shutdown messages of the gensets. 5 10. The GCU as claimed in any of the preceding claims, wherein the master unit is communicatively coupled to a circuit breaker of each of the gensets any one of the communication protocols to automatically start or stop the operation of the gensets. 11. The GCU as claimed in claim 1, wherein the GCU is interfaced with a remote 10 monitoring system and a service tool through the communication units via one of the communication protocols. 12. The GCU as claimed in any of the preceding claims, wherein the communication units comprise CAN (Controller Area Network) ports, UART 15 (Universal Asynchronous Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi module, and the communication protocols comprise CAN bus, UART communication, serial communication, MODBUS, Ethernet, GSM (Global System for Mobile Communications) communication. 20 13. The GCU as claimed in any of the preceding claims, wherein the operating parameters of the engine and the alternator of the gensets comprise engine voltage, engine current, engine frequency, engine phase angle, engine speed, engine power factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine 25 coolant temperature, alternator voltage, alternator current, alternator frequency, alternator phase angle, and alternator power factor. 14. The GCU as claimed in claim 1, wherein the master unit is communicatively coupled with an after treatment system controller through one of the 30 communication protocols for deciding and controlling urea dosing in an exhaust system of the gensets. 49 15. A method for integrated handling of multiple gensets with different operational requirements for power generation application, comprising: receiving and storing, by a memory device of a genset controller unit (GCU), a plurality of operating parameters, a plurality of fault parameters and a plurality of 5 user setting parameters in accordance with each genset along with its operational requirements through a plurality of communication units, wherein the plurality of communication units is configured to communicate with a plurality of genset components and a plurality of external devices using different communication protocols; 10 monitoring and controlling, by a master unit of the GCU, the operating parameters of an engine and an alternator of each genset, wherein the master unit is communicatively coupled with the engine, the alternator and an electronic control unit (ECU) of each genset through at least one of the communication units; monitoring and controlling, by one or more auxiliary units of the GCU, 15 ON/OFF state of one or more supplementary components of the gensets to maintain preset temperature and supplementary constraint for operation of the gensets; regulating, by the master unit, the operating parameters of each genset to synchronize the operational requirements of each of the gensets; determining, by the master unit, auto mains failure (AMF) by continuously 20 monitoring mains voltage from a mains voltage terminal to automatically start the gensets if mains supply is failed or cut off; and displaying the operating, fault and user setting parameters of the gensets, on at least one user interface being connected with the master unit and the auxiliary units of the GCU. 25 16. The method as claimed in claim 15, further comprising: synchronizing, by the master unit, different types and ratings of the gensets by determining at least the operating parameters of voltage, frequency and phase angle of the gensets. 30 17. The method as claimed in claims 15 and 16, further comprising: after synchronizing each of the gensets, operating, by the master unit, each genset in a 50 load sharing mode for controlling genset load based on ratings of the gensets, and a load demand mode for controlling genset load based on an external input into the GCU. 5 18. The method as claimed in claims 15 to 17, further comprising: constantly monitoring and determining, by the master unit, whether values of the operating parameters of the engine and the alternator of each genset are within a range set for the specific genset. 10 19. The method as claimed in claims 15 and 18, further comprising: if the values of the operating parameters of the genset are not within the set range of the genset, indicating and displaying an alert message to the user through the user interface or automatically stopping the operation of the genset. 15 20. The method as claimed in claim 15, further comprising: detecting, by the master unit, any AMF and/or synchronisation failures from the genset, and if the AMF and/or synchronisation failures are detected, indicating and displaying an alert message to the user through the user interface or automatically stopping the operation of the genset. 20 21. The method as claimed in claim 15, wherein the auxiliary units are communicatively coupled with one or more coolant and oil heaters of the gensets through different sensors to maintain preset temperature of coolant and oil in the gensets and to provide ON/OFF command to the heaters. 25 22. The method as claimed in any of the preceding claims, wherein the user interface is designed as a human machine interface (HMI) touch screen display such that the user communicates with the GCU to select and activate at least one of auto/manual operating modes for starting or stopping the operation of the gensets. 30 51 23. The method as claimed in any of the preceding claims, wherein the HMI touch screen display is configured to display warning messages, alarms and shutdown messages of the gensets. 5 24. The method as claimed in any of the preceding claims, wherein the master unit is communicatively coupled to a circuit breaker of each of the gensets any one of the communication protocols to automatically start or stop the operation of the gensets. 10 25. The method as claimed in claim 15, wherein the GCU is interfaced with a remote monitoring system and a service tool through the communication units via one of the communication protocols. 26. The method as claimed in claim 15, wherein the communication units 15 comprise CAN (Controller Area Network) ports, UART (Universal Asynchronous Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi module, and the communication protocols comprise CAN bus, UART communication, serial communication, MODBUS, Ethernet, GSM (Global System for Mobile 20 Communications) communication. 27. The method as claimed in any of the preceding claims, wherein the operating parameters of the engine and the alternator of the gensets comprise engine voltage, engine current, engine frequency, engine phase angle, engine speed, 25 engine power factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine coolant temperature, alternator voltage, alternator current, alternator frequency, alternator phase angle, and alternator power factor. 28. The method as claimed in claim 15, wherein the master unit is communicatively coupled with an after treatment system controller through one of the communication protocols for deciding and controlling urea dosing in an exhaust system of the gensets.