Contents General Information......................6 Function ..........................7 Considerations To Be Taken: ......................7 2.1.1 Different Options ........................7 2.1.2 Systems With One Power Circuit Breaker .................. 7 2.1.3 Systems With Asynchronous/Induction Generators (Special Hardware !!)........7 Signals ............................8 2.2.1 Discrete Inputs........................8 2.2.2 Control Outputs........................
Page 3
Emergency Power (AMF)......................76 3.7.1 Emergency Power With Breaker Logic "PARALLEL" ..............77 3.7.2 Emergency Power With Breaker Logic "OPEN TRANSIT."............77 3.7.3 Emergency Power With Breaker Logic "CLOSED TRANSIT."............77 3.7.4 Emergency Power With Breaker Logic "INTERCHANGE" ............77 3.7.5 Emergency Power With Breaker Logic "EXTERNAL" ..............78 3.7.6 Emergency power With MCB Malfunction ................78 3.7.7...
Page 4
Illustrations And Tables Illustrations Figure 3-1: Control loop ..........................27 Figure 3-2: Step response (Example) ......................28 Figure 3-3: Step responds - governor configuration ..................29 Figure 3-4: CAN bus load/var sharing, wiring diagram.................. 44 Figure 3-5: CAN bus load/var sharing, diagram ................... 44 Figure 3-6: Breaker control logic 'Impulse' .....................
Page 5
WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine, turbine, or other type of prime mover should be equipped with an overspeed (overtemperature, or over- pressure, where applicable) shutdown unit(s), that operates totally independently of the prime mover control unit(s) to protect against runaway or damage to the engine, turbine, or other type of prime mover with possible personal injury...
Function Considerations To Be Taken: 2.1.1 Different Options According to a control unit's configuration, different parameters may be displayed and not all parameters will be avail- able: • Various inputs and outputs will be present or deleted, corresponding to the control configuration (depending on your order).
Signals 2.2.1 Discrete Inputs NOTE All emergency power (Parameter 150 "Emergency power" has to be configured to ON) or Critical (Sprinkler) mode operations (terminal 6 must be configured accordingly; Parameter 223) will be carried out in the TEST and AUTO- MATIC operation modes regardless of the discrete inputs "Automatic 1"...
Page 9
Terminals 54/7 [PCM1-G] Isolated operating / reply external breaker With this input (logical "1") the control is signaled that the genset is operated in isolated operation (the LED "Mains parallel" is off). This discrete input is used to decide whether, after closing the GCB, frequency control (terminal 54 = logical "1") or real power control (terminal 54 = logical "0") is to be carried out.
2.2.2 Control Outputs Terminals 18/19 Readiness for operation Setting this relay signals the readiness for operation of the control. If this relay is disabled, the proper function of the control can no longer be guaranteed. Appropriate actions must be initiated once this relay has been disabled (e.g.
Page 11
Terminals 14/15 Command: close GCB Enabling this relay will close the GCB. If the GCB closing command is configured to continuous current (Para- meter 120), in response to a missing discrete input "Reply: GCB is open" the relay is maintained in its closed state;...
Parameter Configuration can be performed using a PC and the PC program FL-SOFT3 via the serial interface or via the front panel push-buttons and the front panel LC display. Additionally it is possible to configure the unit via CAN bus. The following Baud rates are therefore usable: •...
Basic Data 3.1.1 Version Number (Software Version) Parameter 1 Software version Software version Display of the software version. Vx.xxxx 3.1.2 Configuration Access The control is equipped with a three-level code and configuration hierarchy, which enables it to access various configura- tion screens for different users.
3.1.3 Direct Configuration NOTE To carry out direct configuration, you require a direct configuration cable (order code "FL-CABLE-RS232"), the FL-SOFT3 program (supplied with the cable) and the corresponding configuration files. Please consult the online help installed when the program is installed for a description of the FL-SOFT3 PC program and its setup. Remote configuration: For remote configuration the level CS2 password must be entered via the parameter "password", otherwise, the values can only be read but not written.
3.1.4 Generator Number Parameter 4 Generator number (number of the control on the CAN bus) 1-14 Generator number If several controls are available and these are coupled via a CAN bus, a different number must be assigned to each control for differentiation purposes. The generator number 1 should be assigned even in the case of a single control.
Other Events Switched into operation mode MANUAL BAW Hand Manual mode Switched into operation mode AUTOMATIC BAW Automatik Automatic mode Switched into operation mode STOP BAW Stop Stop mode Switched into operation mode TEST BAW Probe Test mode Switched into operation mode Load TEST BAW Lastprobe Loadtest mode "MCB OFF"...
Measuring WARNING The following values must be entered correctly for the generator to be monitored. Failure to do so may lead to incorrect measuring resulting in damage to or destruction of the generator and/or personal injury or death. Parameter 9 Configuration of the measuring YES/NO Configure...
3.3.2 PTs (Voltage Transformers) WARNING If the value of the following parameter is changed, the values of the following parameters have to be checked: • Generator rated voltage (Parameter 18), • Voltage controller insensitivity (Parameter 64), • Synchronizing dVmax (Parameter 124), •...
WARNING If the value of the following parameter is changed, the values of the following parameters have to be checked: • Threshold mains overvoltage (Parameter 198) as well as • Threshold mains undervoltage (Parameter 200). Parameter 16 Secondary mains voltage transformer [1] 50-125 V;...
Page 22
Parameter 20 Voltage measuring/voltage monitoring Ph-neut./Ph-Ph Volt.meas./mon. Ph-neut/Ph-neut The electrical system(generator, busbar, and mains) consists of the three ---------------- phase conductors and a neutral conductor. Thus the N lug (terminal 0) This parameter must be connected. affects the display. The phase-phase conductor voltages and the phase-neutral voltages are shown in the display.
3.3.4 Generator Current Parameter 21 Generator CT's 10-7,000/{X} A Current transf. The input of the CT ratio is necessary in order to display and control the actual values. The generator 0000/x CT ratio must be selected so that, at maximum power, at least 60 % of the CT nominal current flows.
3.3.5 Mains Current/Mains Power Measurement Mains power actual value measurement via analog input (Package P01) Measurement of the mains power actual value measurement via an analog input T{x} [x = 1-7] is possible if at least one of the analog inputs T{x} [x = 1-7] is a 0/4-20 input. Selection of the analog input is performed with the following pa- rameters.
Page 25
Parameter 27 Mains real power 0/4 mA Analog in.Pmains 9,990-0- 9,990 kW; [4] 6,900-0- 6,900 kW 0000kW The scaleable analog input is assigned a numerical value, which corresponds to the low- Package P01 only est input value " (0 % corresponds to -500 kW; 0 or 4 mA). Parameter 28 Mains real power 20 mA 9,990-0-...
Measurement Units NOTE FL-SOFT3 is not a dynamic program and must be restarted after reconfiguration of a control unit has been started so the changes are reflected in the graphical display of the PC program. Parameter 32 Analog inputs; temperature measurement in ... Celsius/Fahrenheit Temperature in The analog input for temperature measurement may be configured to display in °C or °F.
Controller WARNING Incorrect settings may lead to the errors in measurements and failures within the control unit resulting in destruction of equipment or injury to personnel. Parameter 36 Configuration of the controller YES/NO Configure Parameters are grouped together in blocks to permit quicker navigation through the large controller number of configuration screens.
If an abrupt disturbance variable is applied to the control loop, the reaction of the controlled system can be recorded at the output as a function of time (step response). Tolerance band Rise time rise Settling time sett Overshoot System deviation rise sett Figure 3-2: Step response (Example)
CAUTION The following must be observed regarding the controller setting: • Ensure that the emergency shutdown system is operational. • While determining the critical frequency, pay attention to the amplitude and frequency. • If the two values change uncontrollably: # EMERGENCY SHUTDOWN $ Initial state: The start position of the controller is determined using the initial state of the controller.
Page 30
Parameter 38 P-gain (K ) Proportional-action coefficient 1 to 240 P-gain The proportional-action coefficient K indicates the closed-loop control system gain. By in- Kpr = 000 creasing the gain, the response is increased to permit larger corrections to the variable to be controlled.
3.4.3 Real Power Controller, Set Point Values These screens appear only if the generator real power controller has been configured to "ON" (Parameter 80). NOTE The fixed-value power control does not take into account the mains interchange point. If excess power is generated, it will be exported to the mains.
3.4.4 Frequency Controller Parameter 43 f controller: initial frequency 0-100 % Initial state Analog controller output setting with disabled controller. This value is used as an initial Frequency 000% state value when changing from a real power controller to a frequency controller. Package P01 only Parameter 44 f controller: activation...
Page 33
Three-position controller (standard; Package P01: setting 'THREESTEP') Parameter 49 f controller: insensitivity 0.02-1.00 Hz Freq.controller Isolated operation The generator set point frequency is controlled in such a manner that, deadband 0.00Hz in its adjusted state, the current value deviates from the generator set point frequency by this configured insensitivity at most.
Page 34
Parameter 53 f controller: PWM level 3.0-10.0 V Level PWM If PWM has been selected in Parameter 52 the level of the PWM signal can be adjusted ------------------------ here. Package P01 only Parameter 54 f controller: minimum value 0-100% Stepper sign.frq This parameter permits the operator to clamp or limit the lower analog output value.
3.4.5 Voltage Controller Parameter 59 V controller: initial state 0-100 % Starting point Analog controller output setting with disabled controller. This value is used as an initial voltage 000% value (e.g. when changing from a power factor controller to a voltage controller). Package P01 only Parameter 60 V controller: activation...
Page 36
Three-position controller (standard; Package P01: setting 'THREESTEP') Parameter 64 V controller: insensitivity 00,1-15,0 % Volt.controller ! This value refers to the parameter "rated voltage in system" (Parameter 19). dead band 00.0% Isolated operation The generator setpoint voltage is controlled in such a manner that, in its adjusted state, the current value deviates from the generator setpoint voltage by this configured insensitivity at most.
Parameter 68 V controller: minimum value 0-100% Stepper sign.vol This parameter permits the operator to clamp or limit the lower analog output value. (min.) 000% Package P01 only Example: A 1 to 4V analog output is needed for the voltage controller to operate prop- erly.
Page 38
cos ϕ ϕ ϕ ϕ controller: set point Parameter 74 i0.70 to 1.00 to c0.70 Pow.fact.contr. The desired power factor may be configured here so that the reactive power is regulated setpoint 0.00 in the system. The designations "i" and "c" stand for inductive/lagging (generator overex- cited) and capacitive/leading (generator underexcited) reactive power.
3.4.7 Real Power Controller Parameter 80 P controller: activation ON/OFF Power controller ON....In mains parallel operation the real power is automatically adjusted to the pre-selected set point (Parameter 41 or Parameter 42) when the real power controller is configured ON. The subsequent screens of this function are displayed.
Page 40
External set point value (Package P01) The generator real power set point value may be monitored via an analog input T{x} [x = 1 to 7] if one of the analog in- puts T{x} [x = 1 to 7] is utilized as a 0/4 to 20 mA input. The selection of the analog input is done using the following parameters.
Page 41
Parameter 85 P set point value: range 0-20/4-20 mA Analog input The analog input of the real power controller can be switched here between 0-20 mA 0-00mA and 4-20 mA depending on the set point source. Package P01 only 0-20 mA ..Minimum value of the set point at 0 mA; maximum value at 20 mA. 4-20 mA ..
Page 42
Analog controller (Package P01: setting 'ANALOG') Parameter 91 P controller: P gain 1-240 Power controller The proportional coefficient specifies the gain. By increasing the gain, the response is in- gain Kpr creased to permit larger corrections to the variable to be controlled. The farther out of tol- Package P01 only erance the process is the larger the response action is to return the process to the tolerance band.
3.4.8 Load And/Or Var Sharing Control ensures that under every operating condition (mains parallel operation, isolated operation in parallel with other gensets, or reverse synchronization of the busbar to the mains) the real power (in reference to the relevant rated load) is evenly shared between the generators operating in parallel to the busbar.
Wiring diagram Termination Termination resistor resistor Note: The termination has to be performed with a resisitance, which corresponds to the impedance of the used cable (e.g 120 Ohms) CAN bus CAN bus CAN bus Figure 3-4: CAN bus load/var sharing, wiring diagram Diagram of load/var sharing via the CAN bus: The parameter "Active load sharing factor"...
Page 45
Parameter 96 kW/kvar sharing: load sharing ON/OFF Active power ON....Real power is shared between multiple generators operating in parallel. load-share The generator outputs are distributed depending on the configured value. The subsequent screens of this function are displayed. OFF ..... No real power sharing is carried out, and the subsequent screens of this function are not displayed.
Automatic Parameter 100 Configuration of automatic YES/NO Configure Various groups of parameters are grouped together in blocks to allow to navigate through automatic the large number of configuration screens more rapidly. Selecting "YES" or "NO" has no effect on whether or not control or monitoring etc., is carried out. The input merely has the following effects: YES ....
Page 47
Single generator in mains parallel operation The load-dependent start/stop function is activated when all of the following conditions have been met: • the operation mode AUTOMATIC has been selected • interchange power control (import/export power) has been activated by one of the two discrete inputs ("Automatic 1" or "Automatic 2") ("...
Page 48
Mains parallel operation (mains interchange (import/export) real power control with one generator) General Case 1: Start of the engine If [P > P ] the engine starts. NT.Setpoint NT.actual start Case 2: Stop of the engine If [P < P ] the engine stops.
Page 49
Load sharing with other generators in mains parallel operation The load-dependent start/stop function is activated for every control when the following criteria has been met: • the operation mode AUTOMATIC has been selected • interchange power control (import/export power) has been activated by one of the two discrete inputs ("Automatic 1" or "Automatic 2") ("...
Page 50
Mains parallel operation(mains interchange (import/export) real power control with several generators) General Case 3: Start of the first engine T All GCBs are open. If [P > P ] the first engine is started. NT.setpoint NT.actual start Case 4: Starting of additional engines At least one GCB in the group is closed.
Page 51
Case 4: Generator real power of each individual generator, at which the third engine is started: > P - (P / No. GCB) - P GN.actual rated.tot reserve.parallel rated > 400 kW – (40 kW / 2) - 200 kW = 180 kW. GN.actual.
Page 52
Isolated operation in parallel with other generators The load-dependent start/stop function is activated for every control when the following criteria has been met: • the operation mode AUTOMATIC has been selected • all parameters, such as start power (Parameter 103), stop power (Parameter 106), start delay (Parameter 104), stop delay (Parameter 105) and the frequency set point values (Parameter 10) are identical for all controls involved •...
General Case 7: Start of the engine If [P + > P ] the engine is started. GN.actual.tot reserve.isolated rated.tot Case 8: Stop of the engine If [P + < P ] the engine is stopped. GN.actual.tot reserve.isolated hyst rated rated.tot Example Two generators are used in an isolated operation are used in parallel with other generators.
3.5.3 Interface NOTE For remote acknowledgement of alarms, a remote stop while in idle mode must be performed. If the control is in an iso- lated operation, an acknowledgement combined with a remote start must be performed. Parameter 113 Control via interface COM X1-X5 ON/OFF Control via ON ....
Breaker Parameter 116 Configuration of the breakers YES/NO Configure Parameters are grouped together in blocks to permit quicker navigation through the large breaker number of configuration screens. Selecting "YES" or "NO" has no effect if controlling or monitoring is performed. This parameter has the following effects: YES....
Page 56
Synchronization Synchronization of the GCB The GCB will be synchronized with frequency and voltage correction if the following conditions are met simultaneously. Automatic mode • The operation mode AUTOMATIC is selected • One of the circuit breaker logics (Parameter 117) "PARALLEL" (mains parallel operation), "INTERCHANGE" (mains in- terchange (import/export) real power control) or "CLOSED TRANSIT."...
Page 57
Synchronization of the MCB [PCM1-M] The MCB will be synchronized with frequency and voltage correction if the following conditions are met simultaneously: Automatic mode • The operation mode AUTOMATIC has been selected • One of the circuit breaker logics (Parameter 117) "PARALLEL" (mains parallel operation), "INTERCHANGE" (mains in- terchange (import/export) real power control) or "CLOSED TRANSIT."...
Dead bus start Dead bus start of the GCB The GCB will be closed without synchronization if the following conditions are met simultaneously: Automatic mode • The operation mode AUTOMATIC has been selected • No class F2 or F3 alarms are present •...
Dead bus start of the MCB [PCM1-M] The MCB will close without synchronization if the following conditions are met simultaneously: Automatic mode • The operation mode AUTOMATIC has been selected • The Parameter 135 "MCB dead bus start" has been configured to "ON" •...
Page 60
Open Breaker Open GCB The GCB will be opened both when the relay "Command: GCB close" de-energizes (only if "continuous pulse" has been configured; Parameter 121), and relay "Command: GCB open" is energized. The GCB will be opened under the follow- ing circumstances: •...
3.6.2 Breaker Logic NOTE Using the discrete input "Change breaker logic via terminal 64" (Parameter 219), the breaker logic may be switched between two different breaker logics (description on page 94). The desired standard breaker logic is configured via the following parameter (Parameter 117). If Parameter 218 is configured to "ON", the discrete input terminal 64 is used as a Control input.
Page 62
Breaker Logic "PARALLEL" Parallel operation is enabled via configuration of the parameter (Parameter 117) to "PARALLEL". NOTE operation mode Parallel breaker logic must be selected for the following • Isolated operation • Isolated operation in parallel with other generators • Mains parallel operation In the event of an add-on request the following occurs: •...
Page 63
Breaker Logic "INTERCHANGE" [PCM1-M] Mains interchange (import/export) real power control is enabled via configuration of the parameter (Parameter 117) to "INTERCHANGE". NOTE For this breaker logic to function correctly, the mains power measurement must be connected properly. The power measurement must also be assigned the properly process identifier (C, I, or E). In the event of an add-on request, a change is made from mains to generator supply.
Page 64
Overview PCM1-M STOP TEST MANUAL AUTOMATIC EXTERNAL: Breaker logic "External" The MCB and the GCB are operated in MANUAL operation mode only in this breaker logic mode. In a mains parallel operation, uncoupling from the mains is carried out via the MCB or the GCB in the event of a mains failure. The breakers will not automatically close in emergency power operation.
Page 65
STOP TEST MANUAL AUTOMATIC CLOSED TRANSIT.: Breaker logic "Closed transition / make-before-brake / overlap synchronization" The MCB and the GCB are synchronized, in order to avoid a dead busbar in this breaker logic mode. Immediately after the synchronization of one breaker, the other is opened. Continuous mains parallel operation is not possible. The GCB is ope- The GCB and the MCB are not Synchronization of either the...
Overview PCM1-G STOP TEST MANUAL AUTOMATIC EXTERNAL: Breaker logic "External" The GCB is never synchronized in this operation mode. Decoupling from the mains when in a mains parallel operation is carried out via the GCB in the event of mains faults. The breaker will not automatically close in emergency power opera- tions.
3.6.4 GCB Pulse/Continuous Pulse Closing and opening of the GCB and the MCB are described in the following figures (Figure 3-6 and Figure 3-7). Chang- ing of the breaker control logic is configured using parameter (Parameter 120) and has the described effect on the signal sequence (the operation of the MCB cannot be carried out by means of the continuous pulse).
3.6.6 Synchronization (With Synchronous Generators Only) Parameter 122 Max. perm. differential frequency for synchronization (pos. slip) Synchronize 0.02 to 0.49 Hz df max 0.00Hz The prerequisite for a connect command being issued is that the differential frequency is below the configured differential frequency. This value specifies the upper frequency (posi- tive value corresponds to positive slip "...
3.6.7 Synchronization Time Monitoring (With Synchronous Generators Only) If the following parameter (Parameter 129) is configured to "ON", synchronization time monitoring is performed: If the syn- chronization of the GCB or [PCM1-M] MCB is initiated, the timer is started following the termination of the delayed en- gine monitoring.
3.6.8 Dead Bus Start (With Synchronous Generators Only) If the busbar is de-energized, a dead bus start of the GCB or the MCB is performed. If closing commands for the MCB and the GCB are issued simultaneously, priority is given to the MCB provided the discrete input "Enable MCB" (termi- nal 54) has been enabled.
3.6.9 Connection Functions (With Induction/Asynchronous Generators Only) Parameter 136 Connection of the GCB ON/OFF Switching-on GCB ON ....Generator frequency control is performed with the set point of the mains frequency. The GCB is closed after meeting all connection criteria listed below.
3.6.11 Breaker Monitoring Upon CLOSING - If "GCB monitoring" (Parameter 143) and/or "MCB monitoring" (Parameter 144) have been configured "ON", GCB and/or MCB monitoring is performed (exception: the breaker logic is configured "EXTERNAL" (Para- meter 117). If the breaker cannot be closed after five attempts, a class F1 alarm is issued. If a relay has been assigned re- lay manager functions 74 or 75, it will be energized.
3.6.12 Mains Decoupling NOTE If the mains monitoring (frequency and voltage) is disabled, no mains decoupling is performed. Parameter 145 Decoupling from the mains via ... GCB; GCB->EXT; EXT; EXT->GCB Mains decoupling GCB ..... If a mains failure (Parameter 192 to Parameter 205) occurs the GCB will ------ be opened.
Page 75
NOTE If the mains monitoring (frequency and voltage) is disabled, no mains decoupling is performed. Parameter 146 Decoupling from the mains via ... GCB; GCB->MCB; MCB; MCB->GCB Mains decoupling GCB .... If a mains failure (Parameter 192 to Parameter 205) occurs the GCB will ------ be opened.
Emergency Power (AMF) Parameter 149 Configuration of the emergency power (AMF) YES/NO Configure Parameters are grouped together in blocks to permit quicker navigation through the large emergency number of configuration screens. Selecting "YES" or "NO" has no effect if controlling or monitoring is performed.
3.7.1 Emergency Power With Breaker Logic "PARALLEL" Emergency power: Following a mains fault the "emergency power start delay" (Parameter 151) must expire before the engine is started. Once the voltage and frequency limit values are reached, the MCB is opened and the GCB is closed to the dead busbar.
3.7.5 Emergency Power With Breaker Logic "EXTERNAL" ATTENTION This breaker logic will not permit emergency power in accordance with DIN VDE 0108! Emergency power: Following a mains fault the "emergency power start delay" (Parameter 151) must expire before the engine is started. Once the voltage and frequency limit values are reached, the MCB is opened and the GCB is closed to the dead busbar.
3.8.1 Generator Power Monitoring It is possible to monitor two independently configurable generator power limit values. It is possible to output the tripping to one of these freely configurable relays by means of the relay manager (relay manager function 56 and 80). This function makes it possible to initiate external load shedding.
3.8.2 Mains Power Monitoring It is possible to monitor two independently configurable generator power limit values. It is possible to output the tripping to one of the freely configurable relays by means of the relay manager (relay manager function 67). This function makes it possible to initiate external load shedding.
3.8.3 Generator Overload Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 23; page 23). Function: "Positive real power not within the permissible range" - The single-phase or three-phase measured generator real power is above the configured limit value of the real power. Parameter 164 Generator overload monitoring ON/OFF...
3.8.4 Generator Reverse/Reduced Power Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 23; page 23). Function: "Real power not within the permissible range" - The real power measured in a single-phase or in a three-phase system is below the configured limit value for the minimum load or below the configured value for reverse power.
3.8.5 Load Imbalance Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 24; page 23). Function: "Generator load imbalance not within the permissible range" - The percentage threshold value specifies the per- missible deviation of one phase current to the arithmetic mean value of all three phase currents. Parameter 172 Load imbalance monitoring ON/OFF...
3.8.6 Time-Overcurrent Monitoring NOTE All percentage values refer to a percentage of the generator rated power (Parameter 24; page 23). Function: The PCM1 utilizes a two tier time-overcurrent monitoring with separate adjustable time delays. The threshold val- ues and delays can be selected so that the monitored current level is independent from the tripping time. The level 2 over- current is used as a fast-triggering high-current stage for protection against short circuits.
3.8.7 Generator Frequency Monitoring Function: "Generator frequency not within the permissible range" - The generator frequency is outside of the limit values set for overfrequency or underfrequency. The engine is shut down immediately (class F3 alarm), and an alarm message is dis- played.
3.8.9 Generator Voltage Monitoring The line-to-line (wye) voltage is monitored. Function: "Generator voltage not within the permissible range" - If one or more phases of the generator voltage exceeds the limit values set for overvoltage or undervoltage, the engine is shut down immediately (class F3 alarm) and an alarm message is displayed.
3.8.10 Mains Frequency Monitoring Monitoring the mains frequency is absolutely vital if a generator is operated in conjunction with the infinite grid. In the event of mains failure (e.g. utility power outage) the generator that is operating in parallel with the utility must be automati- cally disconnected from the mains.
3.8.11 Mains Voltage Monitoring Monitoring the mains voltage is absolutely vital if a generator is operated in conjunction with the infinite grid. In the event of mains failure (e.g. utility power outage) the generator that is operating in parallel with the utility must be automatically disconnected from the mains.
Phase/Vector Shift Monitoring d ϕ ϕ ϕ ϕ /dt 3.8.12 A phase/vector shift is a sudden change in the voltage curve that is caused by a large generator load change. The meas- uring circuit detects a change in a single sine wave. This sine wave is compared with a calculated mean value from pre- vious measurements.
3.8.13 Mains Settling Time Parameter 206 Mains settling time 0 to 999 s Mains settling It is possible to delay the synchronization of the generator to the mains for the period of time 000s time configured here. This will permit the user to ensure that the mains voltage is stable while the generator continues to operate in an isolated (parallel) mode or idle offline.
Discrete Inputs Parameter 210 Configuration of discrete inputs YES/NO Configure Parameters are grouped together in blocks to permit quicker navigation through the large dig.inputs number of configuration screens. Selecting "YES" or "NO" has no effect if controlling or monitoring is performed. This parameter has the following effects: YES....
Page 92
Parameter 212 Delay time of the discrete alarm inputs 1-4 Dig.input 1234 A delay time in stages can be assigned to each alarm input. The individual stages are delay 0000 listed below. The discrete input must be present without interruption throughout the delay time in order to be "enabled".
3.9.2 Configuring The Text For The Discrete Inputs NOTE If terminal 6 is configured to "Sprinkler operation" (override or critical mode; Parameter 223) or if a gas engine is se- lected (Parameter 267), the EMERGENCY STOP function must always be assigned to terminal 34. If terminal 34 is not a discrete input, the EMERGENCY STOP function is assigned to the discrete input with the lowest terminal number (this discrete input is then normally the input with terminal number 61).
Block operation mode selector switch via terminal 63 Parameter 217 Disabling the change of the mode using terminal 63 ON/OFF Op.mode blocked OFF ....This terminal is used as an alarm input. by Ter.63 ON ....Terminal 63 is used as control input. If terminal 63 is energized, the operation mode cannot be changed using the pushbuttons on the face of the control unit.
Page 95
Enable 'Close GCB without engine delay' via terminal 67 Parameter 220 Close GCB before the del. engine monit. expires via terminal 67ON/OFF Close GCB asap OFF ..... This terminal is used as an alarm input. by Ter.67 ON....This terminal is used as control input. •...
3.9.4 Terminal 6 ATTENTION The various functions of terminal 6 are enabled at different signal levels! Parameter 223 Function of terminal 6 Function term.6 This parameter is used to assign a function to the terminal 6 discrete input. The following ------------------------ functions may be selected for the discrete input: •...
Page 97
Starting without closing GCB Parameter 224 Perform engine cool down if starting without CB has been selected Start withno GCB ON/OFF cool down ON....After removing the start request, an engine cool down is performed for the Only if terminal 6 has been con- time configured in Parameter 283.
NOTE If "Sprinkler operation" (terminal 6) has been activated, class F2 and F3 alarms are converted to class F1 alarms (ex- ception: terminal 34 or 61 and overspeed). Class F2 and class F3 alarms ! Class F1 alarm "Sprinkler shutdown F1 active": Parameter 225 permits the user to select whether the Sprinkler alarm classes are active during the Sprinkler coasting or if the primary alarm class will be active after the Sprinkler (critical mode) request (termi- nal 6) has terminated.
3.10 Analog Inputs (Package P01) Parameter 226 Configuration of analog inputs YES/NO Configure Parameters are grouped together in blocks to permit quicker navigation through the large analg.inp. number of configuration screens. Selecting "YES" or "NO" has no effect if controlling or monitoring is performed.
Page 100
Scaleable analog input 0/4-20 mA (analog input [T1]-[T3]) NOTE The scalable analog inputs 0/4 to 20 mA can be configured alternatively for the following functions: • Mains interchange (import/export) real power actual value, or • real power set point value. If one of the both functions is assigned to an available 0/4 to 20 mA input T{x} (see Parameter 25 and Para- meter 84), the corresponding analog input T{x} must be configured to OFF.
Page 101
Parameter 229 0/4 to 20 mA input; measuring range 0 to 20 mA / 4 to 20mA Analog input x The measuring range 0 to 20 mA or 4 to 20 mA is selected via this parameter. If 4 to 0-00mA 20 mA is configured and a current of less than 2 mA is measured, the controller assumes [x = 1 to 3]...
Page 102
Pt100 Input (Analog Input [T4]-[T5]) Pt100 inputs may be measured here. The analog input is displayed with its description. Two threshold limits can be moni- tored. The first level initiates a class F1 alarm, the second level initiates a class F3 alarm. Parameter 236 Pt100 input;...
Page 103
VDO Input 'Pressure' (Analog Input [T6]) NOTE The default threshold values are configured in "bar". If the unit "psi" is configured (Parameter 157) the display of the measured values as well as the transmission via the interface appears in "psi". VDO inputs for pressure may be measured here.
Parameter 247 VDO input, pressure; delay time for limit values of class Delay F1 and F3 alarm 0 to 650 s limit 1/2 000s In order to initiate an alarm, the measured value must be over or under (dependent upon Parameter 248) the threshold value (Parameter 245 or Parameter 247) without interruption for at least this time.
Page 105
Parameter 251 VDO input, temperature; limit value for class F1 alarm 40 to 120 °C Limit warning If the measured value exceeds or falls below this configured threshold value (dependent value 000°C upon Parameter 254) for at least the delay time (Parameter 253), the following alarm class is issued.
Page 106
Engine Delayed Monitoring Of The Analog Inputs Parameter 256 Analog inputs; engine delayed monitoring Ana.in 12345678 The analog inputs may be disabled until the engine has reached rated speed ("firing SV.del. NNNNNJNN speed reached"). This parameter specifies which analog inputs are to be constantly en- abled and temporarily disabled by configuring a "Y"...
3.11 Outputs Parameter 258 Configuration of the outputs YES/NO Configure Parameters are grouped together in blocks to permit quicker navigation through the large outputs number of configuration screens. Selecting "YES" or "NO" has no effect if controlling or monitoring is performed. This parameter has the following effects: YES....
3.11.2 Relay Manager The relay manager enables the assignment of an arbitrary combination of functions to each relay. In order to achieve this, each function of the control has its own number. A text, which describes a logical condition that energizes the relay, must now be entered in the configuration menu for each relay.
3.12 Engine Parameter 264 Configuration of the engine YES/NO Configure Parameters are grouped together in blocks to permit quicker navigation through the large engine number of configuration screens. Selecting "YES" or "NO" has no effect if controlling or monitoring is performed. This parameter has the following effects: YES....
3.12.1 Start/Stop Sequence 'Gas Engine' NOTE The configured number of start attempts (Parameter 271) will be performed. without Pickup active: < 15 Hz Time jump 1500 1/min min. speed starter is not reached Start frequency f-contr. + time ZD (1) min.
Starting Sequence If the control is equipped with a three-position frequency controller, a continuous signal (time adjustable via Para- meter 275) is output prior to starting the engine at the "Frequency lower" relay output. The starter is then enabled. Follow- ing the expiration of the ignition delay time (Parameter 269) and if the engine is rotating with at least the configured "minimum speed for ignit."...
Page 112
Parameter Parameter 268 Gas engine; minimum start speed 0 to 999 rpm Min.speed for ! The minimum starter speed can only be detected using an enabled magnetic pick- ignit. 000 rpm up (Parameter 280). This screen is only visible if the parameter "Pickup"...
3.12.2 Start/Stop Sequence 'Diesel Engine' NOTE The configured number of start attempts (Parameter 277) will be performed. 1500 1/min Start frequency f-contr. + time Speed governor Approach idle gas position Engine monitoring activated Start request Start relay Pre-glow 0,5 s 0,5 s Starter Delayed engine...
Page 114
Starting Sequence If the control is equipped with a three-position frequency controller, a continuous signal (time adjustable via Para- meter 281) is output prior to starting the engine at the "Frequency lower" relay output. Following the expiration of this time, the "Pre-glow"...
Parameter 281 Diesel engine; approach idle gas position (time) 0 to 999 s time f lower The duration that the "lower engine speed" signal (see Parameter 280) is output. bef.start 000s with three- step controllers only Parameter 282 Diesel engine; fuel solenoid logic open to stop / close to stop Fuel relay logic open to stop..
3.12.5 Pick-Up Measuring the engine speed can be performed alternatively by means of a Magnetic Pickup, the generator frequency, or a tacho generator. Parameter 286 Pickup; Pickup measurement ON/OFF Pickup input ON....Engine speed monitoring is performed by means of a Magnetic Pickup. Once firing speed has been achieved, the starter disengagement is initi- ated by the MPU measurements.
3.13.1 Maintenance Call Parameter 290 Counter; maintenance call 0 to 9,999 h Service interval A maintenance interval can be specified with this parameter. After the engine has been in 0000h operation for the number of hours configured here, a maintenance message (class F1 alarm) is displayed.
3.13.3 Start Counter Parameter 292 Counter; number of engine starts 0 to 32,000 Set start The start counter is used to display how many times the engine has been started. Follow- counter 00000 ing each starting attempt the start counter is increased by one. This permits the user to dis- play the correct number of starts if this controller is used on an older engine, a starter is replaced, or this controller is to replace an older controller.
3.13.5 Real Time Clock (Package P01) NOTE If several PCM control units are on one common CAN bus all clocks are synchronized daily at 12:00 o'clock (noon) to the time of the control with the lowest control/generator number. This makes it essential that each control unit has a different control number.
3.13.6 Current Slave Pointer A current slave pointer, which records and stores the maximum generator current, is implemented in the control. The dis- play of the maximum generator current can be selected in the Automatic mode by pressing the "Message" push-button. The following screen appears in the display: Parameter 298 Current slave pointer;...
Commissioning DANGER - HIGH VOLTAGE When commissioning the control, please observe all safety rules that apply to the handling of live equipment. Ensure that you know how to provide first aid in the event of an uncontrolled release of energy and that you know where the first aid kit and the nearest telephone are.
Page 123
If the mains parallel operation performs in a satisfactory manner, the synchronization of the mains power circuit breaker (MCB) must be checked: A power failure in the system must be simulated or observed by the controller. During a mains parallel operation, change the operation mode from AUTOMATIC to MANUAL.
Analog output manager (Package P01) NOTE The functions listed below can only be output correctly if the existing version of the control permits this. Func- Output Value Input of the two limit values tion The analog output is disabled. Actual generator real power [dimensionless] Lower power limit (can also be –...
Page 125
Func- Output Value Input of the two limit values tion Analog input [T1] [°C] or (Package P01) [°F] or freely scaleable Analog input [T2] [°C] or (Package P01) [°F] or freely scaleable Analog input [T3] [°C] or (Package P01) [°F] or freely scaleable Lower measured value e.
The designation 0 % stands for either 4 mA or 0 mA; the designation 100 % stands for 20 mA. The values may also be assigned with prefixes (see relay manager function 1). Definition of power factor cos ϕ ϕ ϕ ϕ scaling: According to the scaling of the analog output, the power factor cos ϕ can be output within the range from capacitive values ranging from c0.00 via power factor ϕ...
Relay Manager Output Explanation Alarm class 1 Alarm class 2 Alarm class 3 Firing speed reached (engine runs) Mains failure; undelayed The function reacts according to the status of the breakers. The condi- tions described in chapter "Emer- gency power" apply. Battery undervoltage Operation mode AUTOMATIC Operation mode MANUAL...
Page 128
Output Explanation Discrete input [D16] Auxiliary services i.e. prelube/cooling pumps --Internal-- Centralized alarm (class F1, F2, or F3 alarm; enabled until acknowl- edgement) TEST or AUTOMATIC operation mode selected Generator power watchdog, level 1 MCB is closed GCB is closed --Internal-- Mains parallel operation is desired: disable interlock of GCB <>...
Page 129
Output Explanation Left mains rotating field Engine enable Set engine enable As long as there is a start request for the engine and during cool down (as long as the operation of the engine is enabled, i.e. opera- tion mode AUTOMATIC and dis- crete input 3/5, emergency power, start via interface, manual start, etc.).
Interface Protocol Transmission Telegram Contents (words) Unit Note UGNEXPO Generator voltage delta V V × 10 Generator frequency f Hz × 100 PGNEXPO Actual generator real power P W × 10 Exponents High Byte: PGNEXPO Generator power Low Byte: UGNEXPO Generator voltage Real power set point value PGNWD PGNEXPO...
Page 132
Contents (words) Unit Note Actual mains interchange (import/export) PNTEXPO W × 10 real power Control register 1 Bit 15 = 1 \ Starting enabled (in isolated operation Bit 14 = 1 / or mains parallel operation) Bit 13 = 1 \ --Internal-- Bit 12 = 1 / Bit 11 = 1 \...
Page 133
Contents (words) Unit Note 20 Configuration [T1]-[T4] Display in ... °C °F bar/1 psi/1 no unit Analog input [T4] Bit 15 = Bit 14 = Bit 13 = Bit 12 = Analog input [T3] Bit 11 = Bit 10 = Bit 9 Bit 8 Analog input [T2]...
Page 134
Contents (words) Unit Note 10/3 33 Configuration [T5]-[T8] Display in ... °C °F bar/1 psi/1 no unit Analog input [T8] Bit 15 = Bit 14 = Bit 13 = Bit 12 = Analog input [T7] Bit 11 = Bit 10 = Bit 9 Bit 8 Analog input [T6]...
Page 135
Contents (words) Unit Note 16/1 49 Operation mode Bit 15 = 1 LOAD TEST operation mode Bit 14 = 1 STOP operation mode Bit 13 = 1 TEST operation mode Bit 12 = 1 MANUAL operation mode Bit 11 = 1 AUTOMATIC operation mode Bit 10 = 1 --Internal--...
Page 136
Contents (words) Unit Note 18/1 55 Internal alarm 3 Bit 15 = 1 \ F3: Time-overcurrent, level 2 or Bit 14 = 1 / inverse time-overcurrent, IEC255 Bit 13 = 1 \ F3: Generator overspeed (Pickup) Bit 12 = 1 / Bit 11 = 1 \ Import power 0 kW not reached Bit 10 = 1 /...
Page 137
Contents (words) Unit Note 19/1 58 External alarm 1 Bit 15 = 1 \ Discrete input [D01] Bit 14 = 1 / Bit 13 = 1 \ Discrete input [D02] Bit 12 = 1 / Bit 11 = 1 \ Discrete input [D03] Bit 10 = 1 / Bit 9...
Page 138
Contents (words) Unit Note 22/2 68 Alarm messages IKD2 (SC06) Bit 15 = 1 Failure DI8 of the IKD2 Bit 14 = 1 Failure DI7 of the IKD2 Bit 13 = 1 Failure DI6 of the IKD2 Bit 12 = 1 Failure DI5 of the IKD2 Failure DI4 of the IKD2 Bit 11 = 1...
Page 139
Meaning of the number 69 of the telegram " Currently active display message": Number Meaning GCB synchronization MCB synchronization GCB dead bus start MCB dead bus start Crank Start pause Cool down 000s (000s: the remaining time is displayed) Engine stop! Preglow Purging operation Initial state...
Receiving Telegram The CAN protocol for remote control of the PCM is available upon request. Woodward however recommends the use of a PCK 4. The following three data words can be received by the PCM. Refer to the PCK 4 manual on how to control sev- eral PCM control units.
Framework Conditions To The CAN Bus 4.6.1 Transmission Telegram The data of the following table can be handled by a Gateway PCK4 or a PLC and can be transferred to other busses. A PCM is sending the data via circular CAN messages. The transmitting rate of this communication is 125 kBaud.
4.6.3 Coding Of The Power Setpoint Value The following power values may be pre-specified: constant/baseload power (C power), outgoing/export power (E power) and incoming/import power (I power). The real power set point value is transmitted in binary form using bits 0-13. The control argument must be transmitted in the basis of bits 14 and 15.
List of Parameters Unit number P/N _________________________________ Rev ___________________________________ Version PCM _________________________________________________________________________ Project _____________________________________________________________________________ Serial number S/N _________________ Date _________________________________ Parameter Setting range Default value Customer setting Software version V x.xxxx Enter code 0 to 9.999 XXXX % Y % N % Y % N Direct para.
Page 144
Parameter Setting range Default value Customer setting ONTROLLER CONFIGURATION % Y % N % Y % N YES/NO Configure controller Initial state Frequency 0 to 100 % 50 % P-gain 1 to 240 0.2 to 60.0 s 1.0 s Reset time Derivative time 0.00 to 6.00 s 0.00 s...
Page 145
Parameter Setting range Default value Customer setting ONTROLLER CONFIGURATION % on % off % on % off ON/OFF Power controller 0 to 100 %/s 20 %/s power controller ramp Power limit P max. 10 to 120 % 100 % Power limit P min.
Page 146
Parameter Setting range Default value Customer setting REAKER CONFIGURATION synch 0.02 to 0.49 Hz 0.20 Hz Synchronize df max Synchronize df min 0.0 to 0,49 Hz 0.10 Hz Synchronize dV max 1.0 to 20.0 % 2.0 % 0.02 to 0.26 s 0.24 s Synchronize time pulse>...
Page 147
Parameter Setting range Default value Customer setting MONITORING CONFIGURATION % on % off % on % off Rev./red.power monitoring ON/OFF Rev./red.power resp.value -99 to +99 % 10 % 0,0 to 9,9 s 1.0 s Rev./red.power delay % on % off % on % off Load unbalanced ON/OFF 0 to 100 %...
Page 149
Parameter Setting range Default value Customer setting NALOG NPUTS ONFIGURATION % high % high Monitoring for High limit mon. [high] High limit mon. % low % low low limit mon. [low] % on % off % on % off Analog input 3 scalable ON/OFF Name and unit...
Page 150
UTPUT ONFIGURATION % Y % N % Y % N Configure outputs YES/NO Analg.out.12O121 Parameter 0 to 22 % OFF % OFF 0 to 20 mA Analg.out.12O121 0-00 mA % 0-20mA % 0-20mA 0 to 20 mA % 4-20 % 4-20 4 to 20 mA 0 to 9,990 Analg.out.12O121...
Need help?
Do you have a question about the SEG PCM1x and is the answer not in the manual?
Questions and answers