REFERENCE GUIDE. Copyright 2013 ComAp a.s.

Transcription

1 Compact Controller for Stand-by and Parallel Operating Gen-sets Inteli New Technology Modular Generator Controller Multiple Internal engines application SW configuration MINT - GeCon IG-NT, IG-NTC, IS-NT Software version IGS-NT-GeCon-MARINE, November 2013 REFERENCE GUIDE Copyright 2013 ComAp a.s. ComAp a.s.. Kundratka 2359/17, Praha 8, Czech Republic Tel: , Fax: Technical support hotline: info@comap.cz,

2 Table of Contents Table of Contents... 2 General guidelines... 3 What is described in this manual?... 3 General description... 5 Description of the controller system (with all options)... 5 Comparing of IGS-NT-GeCon-1.7 to the standard IGS-NT-MINT Available documentation... 5 Functions... 6 Modified setpoints... 6 Controller modes in MINT application... 6 Power management PLC functions Multi language support Protections and Alarm management Gen-set operation states Inputs and Outputs Virtual and physical modules Maximum number of configured I/O modules Binary Inputs - Control Binary inputs Status information Binary outputs Breaker control Binary outputs Control loops Binary outputs Status information Binary outputs Fixed protection outputs Binary outputs Power management Binary outputs Configurable Prg. States Analog inputs Analog outputs Analog values Setpoints ProcessControl Basic settings Delays/Timers Analog protect Gener protect Pwr management Sync/Load ctrl Sync/load control adjustment Volt/PF ctrl Volt/PF control adjustment Force value Load shedding Timer settings Act. calls/sms Date/Time Controller configuration and monitoring Direct connection to the PC GenConfig functions InteliMonitor Modbus protocol Value and setpoint codes Technical data

3 General guidelines What is described in this manual? This manual describes IGS-NT-GeCon - MINT software configuration. The Generator controller software configuration is designed for multiple sets applications with internal load sharer and synchronizer. What is the purpose of this manual? This manual provides general information on how to configure and operate the controller. This manual is intended for use by: Operators of gen-sets Gen-set control panel builders For everybody who is concerned with installation, operation and maintenance of the gen-set!! Warnings!! Remote control The IG-NT controller can be remotely controlled. In case that maintenance needs to be done to the gen-set, check the following to ensure that the engine cannot be started. To be sure: Disconnect remote control via RS232 line Disconnect input REMOTE START/STOP or Disconnect output STARTER and output GCB CLOSE/OPEN The controller contains a large number of configurable setpoints, because of this it is impossible to describe all of its functions. These are subject to change from SW version to SW version. This manual only describes the product and is not guaranteed to be set for your application on arrival. Text PAGE Break Return Generator protections REMOTE START/STOP Cyan background (Capital letters in the frame) buttons on the front panel (Italic) set points (Bold) Set point group (Capital letters) binary inputs and outputs Valid for IS-NT only Conformity declaration Following described machine complies with the appropriate basic safety and health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as brought into circulation by us. Note: ComAp believes that all information provided herein is correct and reliable and reserves the right to update at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken. 3

4 WARNING VERY IMPORTANT!!! Be aware that the binary outputs can change state during and after software reprogramming (before the controller is used again ensure that the proper configuration and setpoint settings are set in the controller)!!! Be aware that gen-set can automatically or remotely start!!! Switch the controller to SEM mode and disconnect the Binary outputs Starter and Fuel to avoid unexpected automatic start of gen-set and GCB closing. Dangerous voltage!!! CAUTION!!! The terminals for voltage and current measurement should never be touched. Properly connect the grounding terminals. Do not disconnect the CT terminals for any reason. Adjust set points All setpoints are preadjusted to their typical values. But the set points in the Basic settings settings group!!must!! be adjusted before the first startup of the gen-set.!!! WRONG ADJUSTMENT OF BASIC PARAMETERS CAN DESTROY THE GEN-SET!!! The following instructions are for qualified personnel only. To avoid personal injury do not perform any action not specified in this User guide!!! 4

5 General description Description of the controller system (with all options) NT Family controllers are comprehensive AMF-controllers for single and multiple generating sets operating in stand-by or parallel modes. A modular construction allows upgrades to different levels of complexity in order to provide the best solution for various customer applications. NT Family controllers are equipped with a powerful graphic display showing icons, symbols and bar-graphs for intuitive operation, which sets, together with high functionality, new standards in Gen-set controls. The controller automatically starts the gen-set, closes the Gen-set C.B. when all conditions are met, then stops the engine* (* sw GeCon opens GCB only, not stops the engine) on external signal or by pressing push buttons. Parallel to the Mains operation is a standard feature. Isolated parallel and Power Management System support are optional. Forward and reverse synchronizing, Generator protections, Mains protection including vector shift, load and power factor control are the major functions provided. Interfacing to foreign synchronizers and load sharers is supported. The key feature of the controller is its easy-to-use operation and installation. Predefined configurations for typical applications are available as well as user-defined configurations for special applications. Comparing of IGS-NT-GeCon-MARINE 3.0 with standard IGS-NT GeCon does not take care of Engine control GeCon accepts in SEM mode external control of GCB and Engine GeCon can control the engine via Binary start/stop output signals only see below. The independent Engine controller (e.g. ID-DCU) is expected. Synchronizing and unloading timeouts can be disabled by setpoint setting (or Force value function) All regulations (load, VAr sharing, frequency, voltage) can be disabled by setpoint change or by Force value Interface GeCon to engine controller is provided by I/O wires no by communication line. Active protections does not send stop request to engine (except for SlowStop protection) Available documentation PDF FILE InteliMonitor-2.7-Reference Guide GenConfig-2.6-Reference Guide IGS-NT Communication Guide IGS-NT-2.6 Installation Guide IGS-NT-2.6 Application Guide IGS-NT-2.6-Operator guide.pdf DESCRIPTION Reference Guide for monitoring tool Reference Guide for configuration tool Communication guide for IG/IS-NT controllers. It contains information how to connect control unit and all communication features descriptions Installation guide for IG/IS-NT controllers. It contains technical information about controler and extension modules Application guide for IG/IS-NT controllers. It refers to application and typical installation settings and sites structures Operator guide for IG/IS-NT 5

6 Functions For the IGS-NT-GeCon-MARINE is possible to use IGS-NT-LSM+PMS or IGS-NT-GeCon-LSM+PMS dongle which enables the Load sharing and Power management functions. (both types of dongles have the same function) Modified setpoints Below mentioned are GeCon specific setpoints only. Group Setpoint Option Function Process control StartStopBtn ENABLED DISABLED Standard panel Start/Stop buttons function. Panel Start/Stop buttons are disabled. ProtectionMode ACTIVE NOT ACTIVE 2-nd level protections are blocked. GCB is not controlled. Sync/Load ctrl Sync timeout s NO TIMEOUT Standard MINT function. Unlimited synchronizing time. GCB open level 1-100% NO LEVEL Standard MINT function. No generator power open level detection. GCB open del s NO TIMEOUT Standard MINT function. Unlimited unloading procedure. All above mentioned setpoints can be Forced by Binary input(s) to another value (or switched between ENABLED and DISABLED). Based on setpoint settings there are three possible operational modes HAND SEM - AUT: HAND SEM AUT Basic setting ControllerMode SEM SEM AUT Process control StartStopBtn DISABLED ENABLED ENABLED ProtectionMode NOT ACTIVE ACTIVE ACTIVE Sync/Load ctrl Sync timeout NO TIMEOUT s s GCB open level NO LEVEL 1-100% 1-100% GCB open del NO TIMEOUT s s It is possible to configure (Force value) HAND SEM switching via Binary input. Controller modes in MINT application OFF mode Use OFF mode to block controller functions (even if is switched on). OFF mode is used for controller firmware or configuration change. Binary outputs (e.g. GCB CLOSE/OPEN) are not energized, all closed Binary outputs are opened when controller is switched to OFF mode. Gen-set cannot be started and operated from IGS-NT-GeCon controller no response for panel buttons and Binary input commands. Switching to OFF mode is blocked on running engine to avoid accidental engine stop by mode change or by firmware or configuration programming. 6

7 SEM mode Engine start can be activated from o Engine controller (e.g. ID-DCU, ID-MCU) o GeCon panel Start button o GeCon BI: StartButton o Remotely e.g. from InteliMonitor GeCon BI: ReadyToLoad initiates GeCon Running state - activates Gener protect: Min stab time a Max stab time within the generator electric protections are activated. Gen-set is loaded/unloaded from o GeCon panel GCB button o GeCon BI: GCBButton o Direct GCB hand control o Remotely e.g. from InteliMonitor GCB closing from controller can be blocked by BI: GCB disable (does not block synchronization process) Controller flow chart in SEM mode: 7

8 AUT mode Engine start or Power management is activated from GeCon BI: Sys start/stop GeCon BI: ReadyToLoad initiates GeCon Running state - activates Gener protect: Min stab time a Max stab time within the generator electric protections are activated. Gen-set starts synchronizing and is loaded/unloaded automatically based on o Power management setting o GeCon BI: Sys start/stop GeCon will stop engine started from engine controller when BI Sys start/stop or due to Power management function. 8

9 MAN mode In MANual mode, the controller evaluates configured protections only. All the regulation loops are disabled, not active. Controller s state changes based on sensed signals ReadyToLoad and GCB feedback. In case there is some active protection, this is signalized by appropriate binary outputs. Engine cannot be started from GeCon, GeCon cannot close the GCB, etc..,only opens GCB in cause SD alarm and Setpoint:Protection mode:active. BI:ReadyToLoad Running BI:GCB feedback active Stopped BI:ReadyTo Load - deact BI:GCB feedback not active BI:ReadyTo Load - deact Loaded HAND mode Hand mode is a special type of SEM mode. In Hand mode, the panel Start, Stop buttons are not working, GCB is supposed to be controlled externally. The Hand mode is achieved by setpoints adjustment - see the following picture. IG-EE GeCon MINT generator measuring Vg, Ig, Vb GCB feedback External GCB Close / Open GCB close/open (ReadyToLoad) MCU G G GCB START STOP Speed control (Sync/Load ctrl) RS232 - PC MCU Process control: StartStopBtn = DISABLED ProtectionMode = NOT ACTIVE Sync/Load ctrl: Sync timeout = NO TIMEOUT GCB open level = NO LEVEL GCB open del = NO TIMEOUT External Engine Start / Stop 9

10 Power management Automatic gen-set start / stop function based on load changes and/or Running hours or Engine size. Following functions are available: Power management in kw Guarantees adjustable load reserve (load step) in kw. Suitable for load demand-based optimization. Activation: #Pwr mgmt mode = ABS (kw) Power management in kva Guarantees adjustable load reserve (load step) in kva. Suitable for generator- or busbar dimensioningbased optimization. Activation: #Pwr mgmt mode = ABS (kva) Relative power management in % Guarantees that the engines will be not continuously loaded more than to a certain level, leaving less than selected relative load reserve. Suitable for engine life-based optimization. Activation: #Pwr mgmt mode = REL (%) 10

11 Start/Stop conditions in Power management Reserve Actual Reserve Start condition Stop condition Absolute ARstrt = ΣPg Nom ΣPg Act ARstrt < #LdResStrt ARstp > #LdResStp kw / kva ARstp = ΣPg* Nom ΣPg Act Relative % RRstrt = (ΣPg Nom ΣPg Act ) / ΣPg Nom RRstp = (ΣPg* Nom ΣPg Act ) / ΣPg* Nom RRstrt < #%LdResStrt RRstp > #%LdResStp Where ARstrt ARstp RRstrt RRstp ΣPg Nom ΣPg* Nom ΣPg Act Actual Absolute reserve in kw or kva - for engine start calculation. Actual Absolute reserves in kw or kva - for engine stop calculation. Actual Relative reserve in % - for engine start calculation. Actual Relative reserves in % - for engine stop calculation. Sum of Nominal power of all gen-sets on the bus. Sum of Nominal power of all gen-sets on the bus apart of the one, which is going to be stopped. Sum of Actual power of all gen-sets on the bus = system load. Optional functions in absolute or relative Power management are: - Running hours balancing (equalization), - Load demand (different size) engines swap and - Power management of two or more gen-set groups (bus tie support). 11

12 Running hours balancing The gen-sets priorities are automatically swapped to balance engine running hours. Up to 32 controllers are supported. Activation: #PriorAutoSwap = RUN HOURS EQU Important setpoints: RunHoursBase, #RunHrsMaxDiff LOAD G1 G2 G3 1.controller 2.controller 3.controller Basic settings: Contr.addr = 1 Pwr management: #Pwr mgmt mode = RUN HOURS EQU Priority ctrl = MASTER RunHoursBase = 100 h #RunHrsMaxDiff = 10 h Control group = COMMON Basic settings: Contr.addr = 2 Pwr management: #Pwr mgmt mode = RUN HOURS EQU Priority ctrl = SLAVE RunHoursBase = 200 h #RunHrsMaxDiff = 10 h Control group = COMMON Basic settings: Contr.addr = 3 Pwr management: #Pwr mgmt mode = RUN HOURS EQU Priority ctrl = SLAVE RunHoursBase = 300 h #RunHrsMaxDiff = 10 h Control group = COMMON Different sized engines (Load demand) swap Three running engines (priorities) are swapped based on load demand (one small engine runs on small load and swaps to another one big engine that runs when load increases). Activation: #PriorAutoSwap = LD DEMAND SWAP Important setpoints: #PwrBandContr1, #PwrBandContr2, #PwrBandContr3, #PwrBandContr4, #PwrBandChngDe. LOAD G1 G2 G3 1.controller 2.controller 3.controller Basic settings: Contr.addr = 1 Pwr management: #Pwr mgmt mode = LD DEMAND SWAP Priority ctrl = MASTER #PwrBandContr1 = 1 #PwrBandContr2 = 2 #PwrBandContr3 = 2+3 #PwrBandChngDe = 10 s Control group = COMMON Basic settings: Contr.addr = 2 Pwr management: #Pwr mgmt mode = LD DEMAND SWAP Priority ctrl = SLAVE #PwrBandContr1 = 1 #PwrBandContr2 = 2 #PwrBandContr3 = 2+3 #PwrBandChngDe = 10 s Control group = COMMON Basic settings: Contr.addr = 3 Pwr management: #Pwr mgmt mode = LD DEMAND SWAP Priority ctrl = SLAVE #PwrBandContr1 = 1 #PwrBandContr2 = 2 #PwrBandContr3 = 2+3 #PwrBandChngDe = 10 s Control group = COMMON 12

13 Pwr management of splitted group Important setpoints: Control group, GroupLinkLeft, GroupLinkRight When a Bus-tie disconnects the gen-set group the Power management and Load and Var share can operate separately on each of them. To enable the independent Pwr management, Load and Var sharing between the gensets, group of gensets splitted by bus tie breaker, configure the setpoints as depicted on this picture. LOAD1 LOAD 2 BTB G1 G2 G3 G4 G5 1.controller 2.controller 3.controller 4.controller 5.controller Basic settings: Contr.addr = 1 Pwr management: Control group = 1 GroupLinkLeft = 1 GroupLinkRight = 2 Basic settings: Contr.addr = 2 Pwr management: Control group = 1 GroupLinkLeft = C GroupLinkRight = C Basic settings: Contr.addr = 3 Pwr management: Control group = 2 GroupLinkLeft = C GroupLinkRight = C Basic settings: Contr.addr = 4 Pwr management: Control group = 2 GroupLinkLeft = C GroupLinkRight = C Basic settings: Contr.addr = 5 Pwr management: Control group = 2 GroupLinkLeft = C GroupLinkRight = C BI Group link Control group 1. BTB feedback Control group 2. Load shedding Load shedding fiction is dedicated for tripping of non-essential load in case of high generator current, or drop of generator frequency above/below preadjusted limits, for preadjusted time. All LOAD SHED outputs are activated (closed) to trip the unessential load when gen-set goes to island: a) When GCB is closed after mains fail and gen-set starts in AUT mode. b) When MCB opens from parallel to mains operation in AUT mode. c) Before MCB is opened in SEM mode by button. The load shedding function is active in all controller modes except OFF and MAN. Load shedding has ten steps and each step is linked with its own Load shed x binary output. The non essential load shedding is based on generator current and generator frequency. There is only one level for current load shedding and one level for frequency load shedding for all 10 steps, as well for reconnection level and delay. Load shed can only move from one step to the next, e.g. No LoadShed to LdShed S1 to LdShed S2 to LdShed S10 and vice versa. If manual reconnection of the load is desired, the AutoLd recon setpoint needs to be disabled (AutoLd recon = DISABLED) and the MAN load recon binary input needs to be configured. Rising edge on this input resets the controller to a lower stage, but only if the load is under the Ld recon level at that moment. The current load shedding can be activated in case any of phase current exceeds the adjusted limit. The reconnection is able only in case all of the current values are below reconnection level. 13

14 ManualLdRecon CurShedLev CurRecLev FreqShedLvl FreqRecLvl Load shedding: Ld Shed delay Ld recon delay LdShed stage 1 LdShed stage 2 LdShed stage 10 If no Load Shedding outputs are configured, there is no record to history and no screen timer indication of the activity of this function. On the following pictures, the generator current load shedding is depicted. The current is evaluated from all 3 phases, each phase can activate the load shedding. On the picture, due to transparency, only 3 load shed outputs are depicted, not all 10. The generator frequency based load shedding is in fact the same, but fall below preadjusted limit is watched, instead of exceeding of the limit as in case of current load shedding. Gen-set current Curr shed level BO Load shed 1 BO Load shed 2 BO Load shed 3 closed closed closed Ld shed del Ld shed del Ld shed del Load reconnection automatic -> AutoLd recon = ENABLED Curr recon level Gen-set current BO Load shed 3 opened BO Load shed 2 opened BO Load shed 1 opened Ld recon del Ld recon del Ld recon del Load reconnection manual -> AutoLd recon = DISABLED 14

15 Curr recon level Gen-set current BO Load shed 3 opened BO Load shed 2 opened BO Load shed 1 opened BI Man load recon no action PLC functions Following functions are available in IGS-NT-GeCon-MARINE firmware. Group PLC Block IS-NT-GeCon MARINE 3.0 IG-NT-GeCon MARINE 3.0 Logical function OR/AND XOR/RS Comparators Comp Hyst 16 4 Comp Time 16 4 Comp Win 16 4 Math operations Math Fc 16 2 Ext math Fc 8 2 Interpol Fc 4 1 Regulators PID Ana B 4 2 PID Bin 4 2 Ramp functions Ramp 4 2 Up/Down 4 2 Inc/Dec 2 2 Mov Avg 2 1 Time functions Timer 4 1 Delay 24 8 Others Ana Switch 16 2 Force Hist 4 4 Force Prot 4 4 Jump 4 4 Mux Const. 4 4 Counter 4 1 Decomp 4 4 Convert Multi language support NT Family controllers support up to three Languages that is possible to switch during controller duty. Every terminal (i.e. Remote display or PC-InteliMonitor) can be switched to different language. Use PC-GenConfig - Translator tool to translate texts to another language. Default application archives contain all texts in English only. 15

16 ECU interface customizing The list of available ECU interfaces can be found in GenConfig / Modules / ECU list. In sw GeCon is possible to configure the any ECU, but controller can read information only. Writing any information is not possible. ECUs comunicate via modbus are not supported. 16

17 Protections and Alarm management Protection groups There are two groups of protections in the controller: fix and customer configurable. Setpoint group Analog protections Configurable Analog protect Generator protections Configurable Gener protect Mains protections should not be used in MINT application Fix protections Configurable Fix Mains protect Engine params, Gener protect part of them, Analog protect part of them Protection types Because of limited (adjustable) GeCon influence to the Engine and GCB (depends on configuration and wiring) the GeCon protection system is more focused to fail indication. All Protection types are available because of IGS-NT system compatibility even if some Protection types have the same result in GeCon (e.g. BO, Stp, Sd). Level Protection Abbre GeCon action Record types viation 1 History record Hst None History only 1 Alarm only Al None Alarmlist only 1 Warning Wrn None Alarmlist and History 2 Off load OfL Controller opens GCB without soft Alarmlist and History unloading, gen-set runs 1 minute at Nominal RPM in AUT mode, in SEM mode it runs till operator intervene 2 Breaker Open BO Controller opens GCB without soft Alarmlist and History unloading, gen-set state changes to Running. 2 Slow stop Stp Soft unloading then the GCB opens, BO: Alarmlist and History Stop pulse activation, or deactivation of Remote S/S signal; the gen-set state changes to Stopping. 2 Shutdown Sd Controller opens GCB without soft Alarmlist and History unloading. X Sensor fail Fls Can be indicated when Analog input value is ±6% out of sensor characteristic range. Fls can optionally activate corresponding (e.g. Sd) Analog input protection as well. Alarmlist and History 17

18 Default protections in MINT Fix firmware based Generator: Corresponding setpoints IDMT overcurrent BO Basic settings: Nomin current; Gener protect: 2Inom del It is possible to switch off this protection. IDMT Active power BO Gener protect: OverldStrtEval; 2POvrldStrtEvDel Shortcurrent BO Gener protect: Ishort; Ishort del Default configurable Batt <V, Batt >V Wrn Analog protect: Batt >V; Batt <V; Batt V del EarthFaultCurr BO Gener protect: EarthFaultCurr; EthCurr del Generator frequency: fg<, fg> BO Gener protect: Gen >f; Gen <f; Generator voltage: <V, >V BO Gener protect: Gen >V; Gen <V; Gen V del Reverse power protection is not configured as default protection. This protection can be added using the GenConfig PC sw, in card Protections. Bus voltage and frequency protections it s up to the operator to configure protection in card protections (in GenConfig). Generator voltage and frequency protections - it s up to the operator to configure protection on Generator voltage values. Both protections can be deactivated by value 0 in setpoint. Shutdown override If the Binary input Sd override is closed, all 2 nd level protections are disabled to allow engine run in an emergency situation, e.g. sprinkler devices power supply. All protections are shown in Alarmlist and recorded into History, but the controller doesn t stop the engine because of them. If the input is deactivated and some protections are still active or not yet reset, the controller starts to take these protections into account and consequently stops the engine. Take in account, that the binary outputs, signalizing activation of the particular protection are active independently on the state of BI: SdOverride. All 2 nd level protections are locked out, except of these: - Emergency stop 18

19 Circuit breakers operation sequence, GCB/MCB fail detection Note: In the following text, CB abbreviation is used for MCB or GCB respectively. Related binary inputs: - CB fdb CB feedback binary input - CB fdb neg negative CB feedback binary input. Used for increasing the reliability of CB status evaluated by the controller. In case that it is not configured, negative value of CB fdb is calculated internally within the controller. Related binary outputs: - CB close/open output for circuit breaker. Equals to 1 during the time when CB is requested o be closed. - CB ON coil output for closing coil of the CB. 2s pulse (5s if synchronising is not provided by the particular CB) is used for closing the CB. - CB OFF coil output for opening coil of the CB. 2s pulse (5s if synchronising is not provided by the particular CB) is used for opening the CB. - CB UV coil output for undervoltage coil of the CB. Permanently active, 2s negative pulse (5s if synchronising is not provided by the particular CB) is used for CB opening request - CB status output indicating CB status as evaluated by the controller. This signal is used for lighting LEDs on the panel, switching the regulations, CB fail evaluation, etc. Possible CB sequences: CB close command: BO: CB close/open BO: CB UV coil BO: CB ON coil 1s minimum 1s from UV switching on, together with MinStab time elapsing is necessary before the CB is allowed to close BI: CB fdb BI: CB fdb neg BO: CB status When closing the CB, the CB status LBO switches over only when both feedbacks are in correct position 19

20 Repeated CB close command: BO: CB close/open BO: CB UV coil 1s 2s 2s 1s 2s BO: CB ON coil BO: CB OFF coil BI: CB fdb BI: CB fdb neg If the CB is not closed after the first attempt, it is only reset by OFF pulse and no CB fail is issued. This would be issued after the second unsuccessfull attempt. BO: CB status BI: CB fdb = 0 BI: CB fdb neg = 1 BO: CB status = 0 ON pulse has finished and CB status is not =1. CB fail is issued immediatelly BO: CB fail CB fail fdb mismatch: BO: CB close/open 2s BO: CB UV coil BO: CB ON coil 1s <2s ON pulse is shortened/interrupted and replaced by UV and OFF pulse BO: CB OFF coil 500 ms OFF pulse is activated until both feedbacks return to the correct position +2 seconds. BI: CB fdb BI: CB fdb neg = 1 CB fail If any inconsistence between the two feedback signals is detected, CB fail is issued. BO: CB status = 0 BO: CB fail 20

21 CB open command: BO: CB close/open BO: CB UV coil BO: CB OFF coil BI: CB fdb BI: CB fdb neg 2s Further behavior of UV output depends on the system status. In case of transition to cooling stays off, if the Cb was opened manually and the engine keeps running, it activates again after timeout elapses. During CB opening the CB status LBO is deactivated with change of the first feddback status BO: CB status Transition closing -> opening (opening command is issued during closing pulse): BO: CB close/open BO: CB ON coil <2s Closing pulse is shortened, opening sequence is started immediatelly BO: CB UV coil BO: CB OFF coil 2s CB opening by protection or manual command (button pressed) BI: CB fdb BI: CB fdb neg BO: CB status 21

22 Transition opening -> closing (closing command is issued during opening pulse) BO: CB close/open BO: CB ON coil 2s 2s In this moment, the reason for closing the CB is activated again (e.g. Remote Start/Stop is activated) BO: CB UV coil BO: CB OFF coil Here starts the standard closing sequence see CB close command. BI: CB fdb BI: CB fdb neg OFF a UV pulse is always activated for the full time. manual control (= CB button) is deactivated during opening pulse. BO: CB status Other CB fail reasons: When the BO CB close/open is in steady state and CB feedback is changed, the CB fail is detected immediately (no delay). BO GCB close/open BI GCB feedback Alarm: GCB fail opened closed active Alarm detection: immediatelly BO GCB close/open BI GCB feedback Alarm: GCB fail closed opened active Alarm detection: immediatelly When the BO CB close/open opens, there is 5 resp. 2 sec delay for the breaker to respond before a CB fail is detected. In such case, if CB OFF coil is used for opening the CB and CB fail occurs during opening the CB, the signal CB OFF coil is automatically extended until the breaker opening is detected (evaluated as CB status). 2 sec when the CB is used for synchronizing 5 sec in other cases BO GCB close/open opened BI GCB feedback Alarm: GCB fail Time delay 5 sec active opened 22

23 In case that CB fail is detected after switching the controller on (CB is closed), the CB OFF coil output is activated immediately. 23

24 Gen-set operation states Gen-set can operate in following states Not ready Gen-set is not ready to start Init After controller power supply switch on Stopped No Running indication Starting Waiting for ReadyToLoad signal Running Waiting for GCB connection or start synchronizing Soft load Gen-set power is ramping up Loaded Gen-set is loaded Soft unld Gen-set power is ramping down Stopping Stopping procedure before the BI ReadyToLoad is opened. Stopped Stopped - initial state waiting for engine start Breakers conditions Brks Off Synchro MultIslOp MultParOp GCB opened Gen-set is synchronizing (bus voltage OK, GCB is open) Multiple Island - gen-set is running loaded in island parallel mode (MCB is open, GCB is closed) Multiple Parallel gen-set is running loaded in mains parallel mode (MCB is closed, GCB is closed) 24

25 BIN BOUT AIN AOUT Inputs and Outputs Virtual and physical modules Number of I/O can be extended and project wiring can be reduced using the following extension and virtual modules. Module name Note IGS-NT controller x x x x Number of I/O depends on type. IGS-PTM Standard I/O extension module. IS-AIN Standard I/O extension module. IS-BIN16/ Standard I/O extension module. I-CB x x x x Configurable communication bridge. IGL-RA Green, Red, Yellow LED panel. I-AOUT Analog outputs VPIO Virtual periphery I/O module. SHBIN SHared (virtual) Binary INput module SHBOUT SHared (virtual) Binary OUTput module SHAIN Shared (virtual) Analog Input module SHAOUT Shared (virtual) Analog OUTput module PLC x x x x Programmable (internal) logic module. Maximum number of configured I/O modules Module name Maximum number IGS-PTM 4 IS-AIN8 10 IS- BIN16/8 6 Note Address of the module can be only 1-4. Configuration of this module decrease the maximum number of IS-AIN8 and IS-BIN16/8 and I-AOUT8 which can be additionally configured to IGS-NT controller In case there is connected any IGS-PTM (address 1-4) the maximum number of IS-AIN8 is reduced by this number In case there is connected any IGS-PTM (address 1-4) the maximum number of IS-BIN16/8 is reduced by this number. In case, there is connected any IGL-RA15 module, then one IGL-RA15 means loose of possibility to configure 2 IS-BIN16/8 I-CB 1 Address of any I-CB module must be 1 IGL-RA15 4 Configuration of this module decrease the maximum number of IS-BIN16/8 which can be additionally configured to IGS-NT controller I-AOUT8 4 Configuration of this module decrease the maximum number of IGS-PTM which can be additionally configured to IGS-NT controller VPIO 4 SHBIN 6 SHBOUT 6 SHAIN 2 SHAOUT 2 Take in account that each controller which has configured SHBOUT module should have configured this module with different address, otherwise there will be mismatch of SHBOUT modules on CAN line and Shared outputs will not work correctly Take in account that each controller which has configured SHAOUT module should have configured this module with different address, otherwise there will be mismatch of SHAOUT modules on CAN line and Shared outputs will not work correctly 25

26 Binary Inputs - Control AccessLock int If the input is closed, no setpoints can be adjusted and no commands can be issued from the controller front panel. The setpoints can be changed only externally from another panel, via remote connection (PC direct, internet, modem). As the controller mode (OFF-SEM-AUT-MAN) is one of the setpoints, not even that can be changed. The START, STOP, FAULT RESET and other control buttons are disabled as well. AccessLock D#2 If the input is closed, no setpoints can be adjusted and no commands can be issued from IG/IS-Display #2. AccessLock D#3 If the input is closed, no setpoints can be adjusted and no commands can be issued from IS-Display #3. AccessLock ext If the input is closed, no setpoints can be adjusted and no commands can be issued from any external terminal = via direct/modem/internet connection to the controller. Use these inputs to lock out the selected terminals for setpoint changes and commands. Such a terminal can only be used for monitoring. Alt brightness Active binary input switches controller display backlight to the alternative setting. Alternative intensity of the backlight can be set independently using the controller panel buttons. Input available in IG-NT/NTC and modifications only. For IG-Display and IS-Display modules, this binary input is located in the Power connector and its function is fixed (not configurable). FaultResButton Binary input has the same function as Fault reset button on the controller front panel. Take in account the setpoint Basic settings: Local buttons must be set to EXTBUTTONS or BOTH option, otherwise this input has no influence. HornResButton Binary input has the same function as Horn reset button on the controller front panel. Take in account the setpoint Basic settings: Local buttons must be set to EXTBUTTONS or BOTH option, otherwise this input has no influence. StopButton Binary input has the same function as Stop button on the controller front panel. It is active in SEM mode only. Take in account the setpoint Basic settings: Local buttons must be set to EXTBUTTONS or BOTH option, otherwise this input has no influence. StartButton Binary input has the same function as Start button on the controller front panel. It is active in SEM mode only. Take in account the setpoint Basic settings: Local buttons must be set to EXTBUTTONS or BOTH option, otherwise this input has no influence. GCBButton Binary input has the same function as GCB button on the controller front panel. It is active in SEM mode only. Take in account the setpoint Basic settings: Local buttons must be set to EXTBUTTONS or BOTH option, otherwise this input has no influence. 26

27 All Binary inputs, which simulate controller front panel buttons, are edge (no level) sensitive, and they react on the rising edge only. Minimal input pulse duration is 0,2 seconds. Remote OFF If closed, the controller mode is forced to OFF mode. When opened, controller is switched to previous - original mode. Use this input to block the engine start during service. Remote SEM Active binary input forces the controller mode to SEM mode. When opened, controller is switched to original mode. Remote AUT Active binary input forces the controller mode to AUT mode. When opened, controller is switched to original mode. Use this input to switch the controller to automatic operation, e.g. using the external key switch. Remote MAN Active binary input forces the controller mode to MAN mode. When opened, controller is switched to original mode. Force block 1 6 Three binary inputs for user-specific blocking of programmable protections. If the particular input is active, all the protections with the corresponding Force block X block type are blocked. BINARY INPUT closed Prot. block type = Force block BINARY INPUT FORCE BLOCK closed ForceBlock del Protection active inactive active BinInpDelayX Force value 1 16 If any of the particular 16 input s is active, the Force value function on that corresponding channel gets active, forcing an alternative value to the selected setpoint. Force value function enables to change the setting of some setpoints by activation of binary input or PLC function. It is also possible that the forced setpoint value is based on Analogue input value (generally any analogue value in the controller). IssueActCallC1 3 Rising edge on these binary inputs initiates an active call to be issued via the corresponding channel see setpoints Act. calls/sms Sys start/stop If the input is active, the controller activates BO: Start pulse (in AUT mode only) for 1 second, binary output Remote S/S is also activated. Request to start depends on state of setpoint Pwr management: Pwr management state and, if ENABLED, on the actual need of load reserve. I.e. all controllers in the system should have their Sys start/stop inputs active, but it doesn t mean that all engines are running. If Pwr management: Pwr management is DISABLED, the closed input requests the engine to start regardless of the load reserves. 27

28 If the input opens, based on the state of automat (running, soft load, loaded) the generator is softly unloaded via Load ramp (if there is another gen-set which can take the load) and BO:Stop pulse is activated, as well as the binary output Remote S/S (level signal). In case there is no other gen-set which can take the load, the GCB is opened immediately. Reaction on binary input change is delayed by setpoints Pwr management:#sysamfstrtdel [ s ], Pwr management: #SysAMFstopDel [ s ] in island mode, by 1 sec in mains parallel mode (= input MCB feedback active). Emergency stop If the input is activated, controller immediately trips the GCB. The BO: Stop pulse is not activated, binary output Remote S/S stays active (if engine was running). GeCon is considered as Generator controller, so is not supposed to stop in these cases engine. If this is required, the PLC inside the controller can be used, or copy of this input can be configured to physical binary output to signalize the active input into the engine controller. Sd override If the input is closed, all 2 nd level protections are disabled to allow engine run in an emergency situation, e.g. sprinkler devices power supply. All protections are shown in Alarmlist and recorded into History, but the controller itself doesn t stop the engine due to their occurrence. If the input is deactivated and some protections are still active or not yet reset, the controller starts to take these protections into account and consequently trips the GCB. The binary outputs, which signalize activation of particular protection are active independently on the BI: Sd override activation. In case even these outputs are not requested to be active, the internal PLC can be used (AND function of (particular output and NOT Sd override)) All 2 nd level protections are locked out, except of: Emergency stop HotStndBy The controller behaves like when switched to OFF mode if input is closed. Opens all binary outputs but the output terminals that are configured with inversion are closed. Detection of "running engine" condition and subsequent alarm message "Sd Stop fail" is blocked. The controller shows "Emerg Man" state and the engine can not be started from GeCon panel. Generator current and power (energy) measurement is active in this mode, regardless of the actual state of the engine. After the binary input HotStndBy is open again, the controller recovers to previous mode and behaves according to the actual situation. Should the engine run and any of the conditions to start the engine was active, it will keep the engine running. Function is active in any controller mode and activation of this input is written to history. Load res 2 4 If the input LOAD RES x (2, 3 or 4) is closed, the setpoint set Pwr management: #LoadResStrt X + #LoadResStop X (#%LdResStrt X + #%LdResStop X) will be selected. Higher index has higher priority when more these binary inputs are closed together. When not configured or not active, setpoint set #LoadResStrt 1 + #LoadResStop 1 (#%LdResStrt 1 + #%LdResStop 1) is used. All controllers operating in Power management must have the same Load reserves selected. It is possible to use Virtual periphery to share the signals between more controllers on the CAN bus. In such case one controller is a server which physically has the signals connected and other controllers get these signals via CAN bus. Setpoint set selection depends on the #Pwr mgmt mode if set to ABS (kw or kva), #LoadResStrt X type setpoints are active, if set to REL (%), #%LdResStrt X type setpoints are active. 28

29 BI:Load res 2 SHBOUT(1) CAN2 LBI:Load res 2 SHBIN(1) SHBIN(1) GeCon 1 LBI:Load res 2 LBI:Load res 2 GeCon 2 GeCon 3 The blue colour depicts the connection is done automatically, the yellow colour depicts the connection must be done by operator, using GenConfig PC sw. MinRun power 1 3 When binary input MinRun power 1 or 2 or 3 is closed, the corresponding setpoint Pwr management: #MinRun power 1 or 2 or 3 is selected. Higher index has higher priority when more these binary inputs are closed together. When not configured or not active, minimal running power is 0, i.e. the system works only based on Load reserves. When this input is activated, genset, or group of gensets will never be loaded below the corresponding setpoint: Pwr management: MinRunPower in case of parallel operation with mains. All controllers operating in Power management must have selected the same MinRun power input. It is possible to use Virtual periphery to share the signals between more controllers on the CAN bus. In this case one controller is a server which physically has the signals connected and other controllers get these signals via CAN bus. Priority sw A (Priority switch A) B C D Binary inputs for controller priority selection. Using these inputs, the controller s priority can be changed externally. Priority value Priority Priority sw A 0 or nc Priority sw B 0 or nc Priority sw C 0 or nc Priority sw D 0 or nc Priority value is defined by setpoint PwrManagement:Priority when all Priority switches are opened or not configured. The priority value defined by a combination of binary inputs Priority sw X is accepted with 1s delay. So if a change is made to more inputs simultaneously, it is accepted 1s after the last change sensed. GroupLink If the input is configured, the group linking function is active, i.e. this controller becomes the status server for two groups of gen-sets and informs them about the IM-NT-BTB controller status. If this input is closed, the controller reports BTB status as closed, if open, the controller reports open BTB status. This input can be used for splitting/joining the gensets from/into different groups. In case the gensets are in different groups - PwrManagement: Control group setpoint is adjusted different in both controllers (groups) and the BI: GroupLink is not active, the Load sharing, VAr sharing and power management is not done between the gensets (groups of genstes). As soon as the BI: GroupLink is closed, the Load sharing, VAr sharing and power management became active between the gensets (groups of gensets) with different adjusted Control group setpoint see setpoint: Pwr management:control group [ ]. ManualLdRecon The rising edge on this input switches the controller to the lower Load Shedding stage when Load shedding: AutoLd recon = DISABLED and the load is under Load shedding: Ld recon level. 29

30 GCB disable The input blocks the GCB closing, even if all other conditions for its closing are fulfilled. Valid in all modes. However GCB is blocked to be closed, the synchronization process starts and runs independently on this input state. If you want to lock out the GCB closing during synchronizing loop test, set Sync/Load ctrl: Phase window = 0. This allows the control loop to be tested while actual GCB closing is blocked. Conditions for closing: 1) voltage only on generator side of GCB 2) voltage on both sides of GCB and all synchronizing conditions fulfilled. Startblocking If this input is activated, start signal is not activated (Start pulse or Remote S/S signal) Cyldifevalblk If the signal is active, the protection based on the difference amongst cylinder temperatures is blocked. After signal deactivation, the protection is unblocked immediately. ReadyToLoad This signal is the essential for right functionality of GeCon. As soon as this signal is active, GeCon starts to count down the MinStabTime, and when finished, starts to evaluate configured generator protection if configured by operator. Without activation of this input the GeCon will be sitting in the Starting state and will not proceed into Running state. As soon as this signal is deactivated, GeCon proceed into state Stopping, until still condition is sensed (zero freq measured). In case this signal is lost in Loaded state, the GCB is immediately open. ECU Stopped Eng Engine stop was activated in ECU, not from controller. The controller reflects this situation and also goes to Stop to avoid an Underspeed alarm (and record in the Alarm list). CtrlHB Sense BI "CtrlHBeat sens" should be assigned to the output "CtrlHeartBeat" from the other controller. If input signal does not correspond to right form (log 1 / log ms / 500 ms; +/- 100 ms), BO: "CtrlHBeat FD" (Fail Detect) is activated. This BO can be used for primary controller blocking (switching to Emerg. manual, disconnecting BO,...) and mainly for disconnecting of BI "HotStndBy" of this controller. What means that the backup controller assumes engine control. 500 ms 500 ms >500ms Ctrl HHB Sense CtrlHB FailureDetect GenStandby Controller is automatically forced into the AUT mode as soon as this BI is activated. Controller does not send the start signal to engine controller, engine is supposed to be started externally. GeCon waits till the BI:ReadyToLoad is activated, then starts with MinStabTime count down, synchronization, etc. As soon as the ReadyToLoad signal is activated the behaviour is the same as in AUT mode with activated BI: Sys start/stop, BUT set with activated BI: GenStandby is excluded from power management. As soon as the BI: GenStandby is deactivated, controller is forced into the mode, where was originally and behaves based on the sensing signals. 30

31 GCB close GeCon initiates the synchronization process, if the sync conditions are fulfilled send signal to close GCB. If the dead bus is measured, GCB close command is issued immediately. In case both the BI: GCB close and BI: GCB open are activated, the BI: GCB open wins (generator is unloaded and GCB opened, or sync procedure is terminated). Working only in SEM mode GCB open Active input initiates the soft unload procedure, if the generator load is below: Sync/Load ctrl: GCB open level [ % ] (FV) or GCB open del [ s ] (FV) elapsed, the GCB open command is issued. In case there is no other gen-set on the bus, which can take the load, the GCB is opened immediately. Working in SEM mode only. Gen sync Active input initiates the synchronization process, but the GCB close command is not send automatically. It is up to operator to close GCB by GCB I/O button on GeCon front panel, or use BI: GCB Button, or close GCB externally. The In Sync condition is signalized by BO: InSynchronism. As soon as the BI: Gen sync is deactivated, the synchronization process is terminated. This input is taken in account in SEM and MAN modes only. Function is activated by level (1= sync run, 0= No sync / stop synch). Condition: setpoint: Synchro Enable. Gen unload Active input initiates the soft unload of the generator. The load is ramped towards the Sync/Load ctrl: GCB open level [ % ] (FV), GCB open command is not initiated it is up to operator. In case there is no other genset available to take the load, there is no influence of this input activation. Working in SEM mode only. Function is activated by level (1= Unload, 0= No unload / stop unload.) Sync disable Active input disables synchronization process. Working in both SEM and AUT mode. ExtValue1up Extvalue4up Active input initiates increase of the value ExtValue x (x = 1-4), slope (ratio) of increase is defined by setpoint: Volt/PF control adjustment IG-AVRi output connection Every time refer to corresponding AVR manual before interface connecting. Use no droop AVR. IG-AVRi-TRANS (AC power supply for AVRi) has to be supplied from gen-set voltage. AVRi outputs can be connected as symmetrical: OUT1-OUT2 or unsymmetrical OUT1-GND or OUT2-GND. Potentiometer on the AVRi defines maximal OUT1, OUT2 voltage range. Use symmetrical (OUT1,OUT2) AVRi output to connect the AVRi to AVR auxiliary voltage input. Use unsymmetrical output if an external AVR potentiometer has to be replaced with AVRi. AVRi output voltage should change generator voltage typically in range 10 % of Nominal voltage. For more details please refer to Installation guide chapter AVR interface examples. Out1 - GND [V] Out2 - GND [V] 10 V 2 V AVRi pot set to maximum AVRi pot set to minimum 10 V 2 V AVRi pot set to maximum AVRi pot set to minimum 0 V 0 % AVR DCout bias % 0 V 0 % AVR DCout bias AVRi Out1 or Out 2 to GND output voltage depends on AVRi trim setting % 31

32 [V] 10 V Out1 to Out2 0 % 0 V 50 % AVRi pot = minimum AVRi pot = maximum AVR DCout bias % AVRi output voltage Out1 - GND Out2 - GND Out1 Out2 Bias \ Pot Min Max Min Max Min Max 0 % V -10 V 50 % V 0 V 100 % V 10 V -10 V AVRi Out1 to Out 2 output voltage Voltage control adjustment 1) Set Voltage gain, Voltage int to zero and AVR DCout bias to 50%. 2) Start always with AVRi pot min adjustment (fully counter clockwise). 3) Start the gen-set in SEM Mode to nominal speed, without load. 4) Adjust generator voltage to nominal value by the potentiometer present on the AVR. If there is no potentiometer on the AVR, use AVR DCout bias to adjust the nominal voltage. 5) Change AVR DCout bias to 0% and 100% to check generator voltage control range (typically 10 % of nominal voltage). Adjust voltage control range by AVRi trim. 6) Set AVR DCout bias to be Nominal voltage on generator (50%). 7) When gen-set is running unloaded increase carefully Voltage gain to unstable point and then decrease value by 30 % to insure stable performance. 8) Adjust Voltage int (usually setting to 100% gives optimal performance). To judge optimal adjusting induce generator voltage jumps by AVR DCout bias change or by Nominal voltage change. PF control adjustment The genset should be cca 30 % loaded in parallel to mains and baseload mode. 1) Set the same values PF gain, PF int as in voltage control loop. 2) Set Process control: #SysLdCtrl PtM = BASELOAD, #SysBaseLoad = 30 % of Nominal load, #SysPFCtrl PtM = BASEPF, #SysPwrFactor = ) Start and synchronize the gen-set in SEM Mode by pressing GCB ON/OFF 4) When running in parallel 30% loaded increase slowly PF gain to unstable point and then decrease value by 30 % to insure stable performance. 5) Adjust PF int (usually setting to 100% gives optimal performance). To judge optimal adjusting induce generator power jumps by SysBaseLoad change or by soft changes of AVR DCout bias. Force value:extvalue1 rate [ X/s ] (FV) (2,3,4) ExtValue1down ExtValue4down Active input initiates decrease of the value ExtValue x (x = 1-4), slope (ratio) of decrease is defined by setpoint: Volt/PF control adjustment IG-AVRi output connection Every time refer to corresponding AVR manual before interface connecting. Use no droop AVR. IG-AVRi-TRANS (AC power supply for AVRi) has to be supplied from gen-set voltage. AVRi outputs can be connected as symmetrical: OUT1-OUT2 or unsymmetrical OUT1-GND or OUT2-GND. Potentiometer on the AVRi defines maximal OUT1, OUT2 voltage range. 32