GEMPAC User Manual Version 3

GEMPAC Manual Version 3.0

GEMPAC User Manual Version 3.0

Page 1 of 88

1

GEMPAC Basics

7

1.1 Standard functions 7 1.2 Application control 7 1.3 Language 7 1.4 Standard control functions 7 1.5 Generator protection functions 8 1.6 Function list 8 1.6.1 Loss of mains protection package 8 1.6.2 Generator add-on protection package 8 1.6.3 Voltage/var/cos ! control 8 1.6.4 Analogue controller outputs 8 1.6.5 Start/stop relay outputs 8 1.6.6 Serial communication 8 Error! Bookmark not defined. 1.6.7 Configurable I/O extension cards 1.7 Hardware 9 1.8 Terminal strip overview (QSK45) 11 2

Terminal strip, explanation (QSK45)

2.1 Slot #1, power supply and binary I/O 2.2 Descriptions 2.2.1 Inputs 2.2.2 Alarm relays 2.3 Slot #2, Communication 2.4 Slot #3, Load Sharing and Additional Control 2.4.1 Engine Shut downs and Controls 2.5 Slot #4, analogue output 2.6 Slot #5, AC measuring 2.7 Slot #6 Digital Inputs 2.7.1 Description of Functions 2.8 Slot #7, Analogue and Engine Interface Card. 2.9 Slot #8, Spare inputs 3

Example Wiring Diagrams

3.1 3.2 3.3 3.4 3.5 3.6 3.7 4

AC connections Load sharing lines Binary inputs Analogue Inputs, External Set-points Optocoupler outputs for external counter Di s play I/F cable PC Interface Cable Display unit

4.2 Pushbutton functions 4.3 Display functions 4.3.1 First line in display (daily use display functions) 4.3.2 Second line in display (daily use display) 4.3.3 Second line in display (menu system) 4.3.4 Second line in display (alarm and event list) 4.3.5 Third line in display (daily use display) 4.3.6 Third line in display (parameter menu display) 4.3.7 Fourth line in display (parameter menu display)


13

13 14 14 14 16 17 17 19 20 20 21 22 24 25

25 26 27 28 29 30 31 32

32 33 33 34 34 34 34 35 35

Page 2 of 88

1

GEMPAC Basics

7

1.1 Standard functions 7 1.2 Application control 7 1.3 Language 7 1.4 Standard control functions 7 1.5 Generator protection functions 8 1.6 Function list 8 1.6.1 Loss of mains protection package 8 1.6.2 Generator add-on protection package 8 1.6.3 Voltage/var/cos ! control 8 1.6.4 Analogue controller outputs 8 1.6.5 Start/stop relay outputs 8 1.6.6 Serial communication 8 Error! Bookmark not defined. 1.6.7 Configurable I/O extension cards 1.7 Hardware 9 1.8 Terminal strip overview (QSK45) 11 2


2.1 Slot #1, power supply and binary I/O 2.2 Descriptions 2.2.1 Inputs 2.2.2 Alarm relays 2.3 Slot #2, Communication 2.4 Slot #3, Load Sharing and Additional Control 2.4.1 Engine Shut downs and Controls 2.5 Slot #4, analogue output 2.6 Slot #5, AC measuring 2.7 Slot #6 Digital Inputs 2.7.1 Description of Functions 2.8 Slot #7, Analogue and Engine Interface Card. 2.9 Slot #8, Spare inputs 3

Example Wiring Diagrams

3.1 3.2 3.3 3.4 3.5 3.6 3.7 4

AC connections Load sharing lines Binary inputs Analogue Inputs, External Set-points Optocoupler outputs for external counter Di s play I/F cable PC Interface Cable Display unit

4.2 Pushbutton functions 4.3 Display functions 4.3.1 First line in display (daily use display functions) 4.3.2 Second line in display (daily use display) 4.3.3 Second line in display (menu system) 4.3.4 Second line in display (alarm and event list) 4.3.5 Third line in display (daily use display) 4.3.6 Third line in display (parameter menu display) 4.3.7 Fourth line in display (parameter menu display)


13

13 14 14 14 16 17 17 19 20 20 21 22 24 25

25 26 27 28 29 30 31 32

32 33 33 34 34 34 34 35 35

Page 2 of 88

4.3.8 Fourth line in display (daily use display) 4.4 Menu overview 4.4.1 Jump functions 4.4.2 Navigating in the menus 4.4.3 Setup menu system 5

Menu set-points

5.1 Standard Protection Functions 5.1.1 Mains/BUS Voltage 5.1.2 Mains/BUS Frequency 5.1.3 Generator Voltage 5.1.4 Generator Frequency 5.1.5 Generator Reverse Power 5.1.6 Generator Overcurrent 5.1.7 Generator Overload 5.1.8 Generator Current Unbalance 5.1.9 Generator Voltage Unbalance 5.1.10 Generator Reactive Power Import (loss of excitation) 5.1.11 Generator Reactive Power Export (overexcitation) 5.2 Analogue Inputs (4…20mA input) 5.2.1 Inlet Air Restriction Left 5.2.2 Inlet Air Restriction Right 5.2.3 Exhaust Gas Temperature Left 5.2.4 Exhaust Gas Temperature Right 5.2.5 4...20mA Input 1 5.2.6 4...20mA Input 2 5.2.7 4...20mA Input 3 5.2.8 4...20mA Input 4 5.3 Analogue Input (PT100 input) 5.3.1 Container Temperature 5.3.2 Panel Temperature 5.4 Tacho Input 5.4.1 Engine Speed 5.5 Binary Input 5.5.1 Emergency Stop Energised 5.5.2 ECM Warning 5.5.3 ECM Shutdown 5.5.4 Air Flaps Closed 5.5.5 AVR Over Voltage 5.5.6 Excitation Loss 5.5.7 Fuel Spillage 5.5.8 Fan Fail 6

Control Menu

6.1 Standard Control 6.1.1 Synchronisation 6.1.2 Sync. Blackout 6.1.3 General Failure (Sync. Fail) 6.1.4 Power Ramp Down 6.2 Gempac Control 6.2.1 Cooling Time


35 36 36 36 36 38

38 38 39 40 41 42 42 42 43 43 43 43 44 44 44 45 45 46 46 46 47 48 48 48 49 49 50 50 50 50 50 51 51 51 51 52

52 52 52 52 52 53 53

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6.2.2 Start Time 6.2.3 Synchronisation type. 6.2.4 General failure (sync. fail.) 6.3 PI controller 6.3.1 Deadband (+/- value) 6.3.2 Gain factor 6.3.3 ON-time 6.3.4 Frequency controller 6.3.5 Power controller 6.3.6 Power ramp up 6.3.7 Power ramp down 6.3.8 Power/frequency control mix factor 6.3.9 Voltage controller. 6.3.10 VAR controller 6.3.11 VAR/Voltage control mix factor 6.3.12 Power factor (PF) controller 7

Power Menu

7.1 Peak Lopping 7.1.1 Mains power 7.1.2 Daytime Period 7.1.3 Start First Generator 7.1.4 Stop First Generator 7.1.5 Start Next Generator 7.1.6 Stop Next Generator 8

System Menu

8.1 Settings 8.1.1 Nominal settings 8.1.2 Transformer 8.1.3 External Communication 8.1.4 Auto Detection Run 8.1.5 Battery Low Voltage Alarm 8.1.6 Load Share Line Selection 8.1.7 Tacho Input Configuration 8.1.8 Total Running Time 8.2 System setup 8.2.1 Nominal settings 8.2.2 Transformer 8.2.3 Controller settings 8.2.4 External communication control 8.2.5 External Communication Protection 8.2.6 Date and time (internal clock) setting 8.2.7 Auto detection of running signal 8.2.8 Battery under voltage alarm 8.2.9 Language 8.2.10 Number of teeth 8.2.11 User password 8.2.12 Service menu 8.2.13 Application menu 8.2.14 Transferring set points by CAN-bus. 9

Extern Communication Control


53 53 54 55 55 55 56 57 58 58 58 59 59 59 59 60 61

61 61 61 62 62 62 63 64

64 64 64 64 64 65 66 67 67 68 68 68 68 69 69 69 70 70 70 70 71 71 71 72 73

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10 11

Mode selection PEAK-LOPPING

11.1 Fault conditions 11.1.1 Loss of Mains 11.1.2 Loss of Can-bus Connection 11.2 Engine Deloading 12

12.1 12.2 13

13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 14

14.1 14.2 14.3 14.4

Utility Software

Configurable Spare Inputs Control settings libraries for operation mode System Logic

Log Event Engine Starting Mode Initiate Warning - Fail Class 0 Engine Stop - Fail Class 1 Emergency stop - Fail Class 2 Shutdown - Fail Class 3 Emergency shutdown - Fail Class 4 Electrical Fault - Fail Class 5 General data

Technical specifications Unit dimensions Display dimensions Panel cutout for display


74 75

75 75 75 76 77

78 80 82

82 82 83 83 83 83 83 84 84 85

85 86 87 88

Page 5 of 88

Warnings and legal information

This manual gives guidelines to the installation of the GEMPAC generator control and protection unit. The drawings should be used as guidance only. Installing and operating the GEMPAC product implies work with dangerous currents and voltages, and therefore only qualified personnel should only carry it out. Care must be taken during the installation to protect the terminals against static discharges. Once the units are installed and connected, these precautions are no longer necessary. If there is any doubt about how to install or operate the system on which the GEMPAC product is measuring, you should contact your next level of technical support.


Page 6 of 88

1

GEMPAC Basics

1.1

Standard functions

The GEMPAC is a protection and control unit for a generator driven by a diesel engine or a turbine. It will carry out all necessary tasks to control and protect a generator, regardless of the use of the generator. This means that the GEMPAC can be used for several application types such as: • • •

Stand-alone generator Multiple generator load sharing control Fixed load to mains/base load

The GEMPAC measuring system is true RMS 3-phase measurement of generator voltage, generator current and bus (mains) voltage. 1.2

Application control

The GEMPAC GEMPAC has the ability to switch between different applications dependant upon the generator type. Switching between applications re-asssgns inputs and outputs on the unit as well as change nominal settings and protections levels The Gempac software ver. 2.10.0 and higher can be used for four applications, GempacQSK45, Twinpack, QSK60 and 50G3 The application is selected in menu 5000, which can only be entered by the “JUMP” button. When selecting an application, the GEMPAC will reset it self and all previous settings. The application specific menus will only be available when the right application is selected. The selected application will be stored even if new software is downloaded to the GEMPAC. No. 5000 5001

Setting Application Application

Selection display Gempac – QSK45 Twinpack Gempac – QSK60 Gempac – 50G3

Setting 1 2 3 4

Factory setting 1

Ensure that the correct application is selected for the generator. This manual will address the specific settings and layout of the QSK45 application, for information on the input/output configurations of other generators please refer to appendix 1 NOTE: The setting and I/O in this manual are based on the QSK45 application, for 50G3, QSK60 and Twinpack information please refer to Appendix 1. 1.3

Language

English, German, French or Spanish language can be chosen via the system menu structure. 1.4 • •

•

Standard control functions Static synchronisation Dynamic synchronisation o Frequency matching Voltage check o Breaker delay time compensation o o Check phase sequence Fixed load (base load) running of the generator


Page 7 of 88

• • • •

Fixed frequency running of a stand-alone generator Load sharing between generators with power and frequency control Relay outputs to close/open generator breaker Adjustable ramp up/down of generator load

1.5

Generator protection functions

Protective functions can be selected to activate 5 configurable Fail Class Outputs, see section 13 System Logic. These alarms can be selected with definite or inverse time characteristic: • •

Reverse power Overcurrent (2 levels)

1.6

Function list

GEMPAC has the following functions

1.6.1

Loss of mains protection Over and under voltage (busbar/GPC: generator and busbar) Over and under frequency (busbar/GPC: generator and busbar) Vector jump Df/dt (ROCOF)

1.6.2

Generator protection Over and under voltage (generator) Over and under frequency (generator) Overload Current unbalance Voltage asymmetry Reactive power (import (excitation loss)/export)

1.6.3

Voltage/var/cos ! control Selectable (via binary inputs or (optional) serial interface) functions: Constant voltage (stand-alone) Constant reactive power (parallel with mains) Constant power factor (parallel with mains) Reactive power sharing (parallel with other generators, island operation) Constant voltage (stand-alone/synchronisation)

1.6.4

Analogue controller outputs +/-20 mA for speed governor +/-20 mA for voltage/var/cos ! control

1.6.5

Start/stop relay outputs Synchronisation with relay outputs for governor control

1.6.6

Serial communication Can-open

1.6.7

Analogue Measurements 4, 4…20 mA inputs, 2 PT100 inputs, tacho input


Page 8 of 88

1.7

Hardware

The GEMPAC housing is divided into board slot positions, the unit is divided like this: Position Slot #1 Slot #2 Slot #3 Slot #4 Slot #5 Slot #6 Slot #7 Slot #8

Terminals 1-28 29-36 37-64 65-72 73-89 90-125 98-125 126-133 Spare

Besides the slots there is an additional board where the communication ports are placed. The RS232 PC service port for the utility software and the display port.


Page 9 of 88

G E M P A C U s e r M a n u a l V e r s i o n 3 . 0

1 .7 .1 .1

1

2

3

4

5

6 7

8

9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 26 27 28

29 30 31 32 33 34 35 36

SLOT #1 SLOT #3

SLOT #2 SLOT #4 37 38 39 40 41 42 43 44 45 46 47 48 49 50

51 52 53 54 55 56 57 58 59 60 61 62 63 64

Service port

65 66 67 68 69 70 71 72

DISPLAY

t k i r o b e i k h w n o i e c P h m c r f l a l e A S

73 74 75 76 77 78

79 80 81 82 83 84

85 86 87 88 89

90 91 92 93 94 95 96 97

SLOT #5 SLOT #7

SLOT #6 SLOT #8 98

99 100 101 102 103 104 105 106 107 1 08 109 110 111

112 113 114 115 116 117 118 119 120 121 122 123 124 125

126 127 128 129 130 131 1 32 133

P a g e 1 0 o f 8 8

1.8

Terminal strip overview (QSK45)

1.8.1.1

Slots #1, #2, #5 and #6, Diagram 2

ALARM RESET MODE ENABLE VOLTS DOWN VOLTS UP

DIGITAL

MODE SELECTOR 3

INPUT

MODE SELECTOR 2 MODE SELECTOR 1 COMMON

COMMON AIR FLAPS CB OPEN CB CLOSE EMERGENCY STOP ENERGISED CB TRIPPED COMMON kW PULSE kVAR PULSE

CLOSE BREAKER L3 BUSBAR SPARE

L2

L1

VOLTAGE

D i a g r a m 1 – O v e r v i e w o f t e r m i n a l l a y o u t

1.8

Terminal strip overview (QSK45)

1.8.1.1

Slots #1, #2, #5 and #6, Diagram 2

ALARM RESET MODE ENABLE VOLTS DOWN VOLTS UP

DIGITAL

MODE SELECTOR 3

INPUT

MODE SELECTOR 2 MODE SELECTOR 1 COMMON

COMMON AIR FLAPS CB OPEN CB CLOSE EMERGENCY STOP ENERGISED CB TRIPPED COMMON kW PULSE kVAR PULSE

CLOSE BREAKER L3 BUSBAR SPARE

L2

VOLTAGE

L1 CB TRIP

NEUTRAL L3 GENERATOR

EMERGENCY STOP

L2

OPEN BREAKER

S2

VOLTAGE

L1

S1 STATUS

POWER

S2

YELLOW CURRENT

S1

0V

S2

24V

S1


BLUE CURRENT

RED CURRENT

Page 11 of 88

1.8.1.2

Diagram 3, Slots #3, #4, #7 and #8

V OUT 0 V OUT + ANALOGUE OUTPUTS

SPARE BOARD Hz OUT 0 Hz OUT +

SPARE

CLOSE AIR FLAPS

ALARM RESET

ENGINE START CRANK

ENGINE RUN

SPEED SELECTION

COMMON ECMIDLE/RATED SPARE COMMON SPEED DECREASE SPEED INCREASE MANUAL/AUTO SWITCH

FAN FAIL ENGINE STOP EXTERNAL SET POINT VOLTS EXTERNAL SET POINT POWER

REMOTESTART TACHO MAGPICK-UP LOCAL CONTROL ON CLOSE BREAKER REQUEST OPEN BREAKER REQUEST

PT100 INPUT2

ENGINE START FUELSPILLAGE EXCITATION LOSS

PT100 INPUT1

AVR OVERVOLTAGE ECM COMMON SHUTDOWN

4-20mA INPUT4

ECM COMMON WARNING 4-20mA INPUT3

4-20mA INPUT2

4-20mA INPUT1


Page 12 of 88

2


For the relay outputs the following terms will be used: NO means Normally Open NC means Normally Closed COM. means common terminal for the relay in question

2.1 Term. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Slot #1, power supply and binary I/O Function Power supply Power supply Status out COM Status out NO Relay 1 NO Relay 1 COM Relay 1 NC Relay 2 NO Relay 2 COM Relay 2 NC Relay 3 NO Relay 3 COM Relay 3 NC Relay 4 NO Relay 4 COM Relay 4 NC Relay 5 NO Relay 5 COM Relay 5 NC Optocoupler COM Optocoupler OP 1 Optocoupler OP 2 Digital input Digital input Digital input Digital input Digital input Common

Description

GEMPAC, System Healthy GEMPAC, System Healthy Open Breaker Open Breaker

Ferrule K3 J2 K3 K102 (none) GY12 GY3

Emergency Stop Emergency Stop Emergency Stop Circuit breaker trip Circuit breaker trip Circuit breaker trip Spare Spare Spare Close Breaker Close Breaker

K799 K905 C2 C1 -

Spare Spare Spare CB Tripped Emergency Stop Energised CB Closed CB Open Air Flaps J2 (0V)

K55 K797 X2 X3 K793 J2


GY10 GY3

Page 13 of 88

2.2

Descriptions of I/O

2.2.1

Inputs

The inputs 23-27 on slot #1 are control inputs. Terminal 28 is the common (J2)

2.2.1.1

Input 23:

CB Tripped, this input will go high when the Circuit Breaker connecting the generator set to the mains Busbar has tripped out on its own overcurrent protection, for the QSK45 genset this will not indicate a GEMPAC initiated trip or other auxiliary protection trip. 2.2.1.2

Input 24:

Emergency stop, will be energised high when the system is running normally, this signal is required to keep relay 2 energised. 2.2.1.3

Input 25:

CB Closed, is energised high when the circuit breaker is in the closed position. 2.2.1.4

Input 26:

CB Open, is energised high when the circuit breaker is in the open position. 2.2.1.5

Input 27:

Air Flaps, this is energised high when the air flaps are closed.

2.2.2

Alarm relays

5 relays are mounted in the power supply and binary I/O board in slot #1. Relays 1-5 are preconfigured.

2.2.2.1

Relay 1:

Open Breaker, this relay will open the circuit breaker immediately when required 2.2.2.2

Relay 2:

Emergency Stop: This relay is energised closed to maintain the emergency stop loop; if an emergency stop is required the GEMPAC will de-energise these contacts and stop the engine.


Page 14 of 88

2.2.2.3

Relay 3:

Circuit Breaker Trip: This relay is energised closed to maintain the circuit breaker undervoltage trip loop; if a circuit breaker trip is required by the GEMPAC this will deenergise the contacts and trip the breaker

2.2.2.4

Relay 4:

Spare.

2.2.2.5

Relay 5:

Circuit Breaker Open, this relay will close the circuit breaker if the conditions set in the GEMPAC are met. If the alarm function is enabled, an alarm will always be displayed on the multi-line 2. Furthermore you can activate a fault code, which is selected from 6 levels, see section 13. In general failure conditions (sync. failure) the regulation stops and the running situation is frozen. Acknowledge of the alarms is done in one of two ways, either the binar y input 96 is used or the select button on the display (the second will only clear alarms present in the GEMPAC) The alarm acknowledge input acknowledges all present alarms and the alarm LED will change from flashing to steady light, it will also reset the alarms on the ECM by closing Relay 7 The display can be used in the alarm information window. This is shown if you press the “INFO” pushbutton. The alarm information window displays one alarm at a time and whether it is acknowledged or not. If it is unacknowledged, move the cursor to “ACK” and press select to acknowledge it. Use the up and down buttons to step in the alarm list. When alarm LED is flashing if there are some unacknowledged alarms, when it is on continuously there are only acknowledged alarms present. 2.2.2.6

Status relay, slot #1

The status relay on the power supply board is a normally closed relay with the purpose of processor and power supply supervision. This relay cannot be configured to any other alarms. This relay is not utilised in the GEMPAC system. 2.2.2.7

kWh and kvarh counter

The multi-line 2 monitors the energy production of each unit and it has pulse-outputs for kWh and Kvar.h measurement. The number of pulses depends on the nominal output of the generator as follows: " Pnom < 100 kW 1 pulse/kWh Pnom 100-1000 kW " 1 puse/10 kWh " Pnom > 1000 kW 1 pulse/100 kWh

The pulse length is 1 s/pulse; this feature is not utilized in the GEMPAC system


Page 15 of 88

2.3

Slot #2, Communication

Can-open Term. 29 30 31 32 33 34 35 36

Function Can-H GND Can-L Can-H GND Can-L Not used Not used

Description The can is based on the can-open protocol

The serial communication line should be terminated at either end with a resistor value of 100 to 120 Ohms Use shielded twisted pair cable and ensure that it is properly earthed.


Page 16 of 88

2.4

Slot #3, Load Sharing and Additional Control

Term. 37 38 39 40

Function Load sharing line Load sharing line Load sharing line External set points

Description Parallel load sharing line Parallel load sharing line Parallel load sharing line In peak lopping mode: Transducer input from Pmains measuring External power setting level External power setting level External power setting level ECM Common Warning ECM Common Shutdown AVR Over Voltage Excitation Loss Fuel Spillage Engine Start Open Breaker Request Close Breaker Request Local Control On Remote Start Manual/Auto Switch Speed Increase Speed Down J2 (0V) ECM Idle Rated Selector ECM Idle Rated Selector Alarm Reset Alarm Reset Close Air Flaps Close Air Flaps Spare Spare

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

External set points External set points Digital input Digital input Digital input Digital input Digital input Digital input Digital input Digital input Digital input Digital input Digital input Digital input Digital input Common Relay 6 COM Relay 6 NO Relay 7 COM Relay 7 NO Relay 8 COM Relay 8 NO Relay 9 COM Relay 9 NO

2.4.1

Engine Shut downs and Controls

Ferrule PL2 PL1

K613 K615 K65 K809 K795 K1014 K1002 K1006 K1012 REMS K1016 K1020 K1028 J2 K705 K709 K705 K707 K719 K1

There are a number of engine specific shutdowns and fault indication marshalled at the GEMPAC unit. 2.4.1.1

Input 43

ECM Common Warning, this is an input form the ECM indicating a common warning 2.4.1.2

Input 44

ECM Common Shutdown, this is an input form the ECM indicating a common shutdown 2.4.1.3

Input 45


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AVR Over voltage, this is an input form the AVR indicating an over volt age, nominally this is set in the AVR. 2.4.1.4

Input 46

Excitation Loss, this is an input form the ACB in dicating an excitation loss on the stator. 2.4.1.5

Input 47

Fuel Spillage, this input is from the fuel spillage sensors within the bund of the genset. 2.4.1.6

Input 48

Engine Start, if the conditions are met energising this input momentarily (300ms+) will begin the engine starting cycle. 2.4.1.7

Input 49

Open Breaker Request, energising this input will energise Relay 1 immediately; this function is not inhibited by any other component or logic. 2.4.1.8

Input 50

Close Breaker request, this will begin synch and check synch the generator as required and if programmed allow closing onto a dead/black Busbar. Note: regardless of the operation of the panel Manual/Auto/Remote etc, the GEMPAC will always be in control of the genset during the closing cycle of the breaker, thus preventing uncontrolled breaker closing. 2.4.1.9

Input 51

Local Control On, this input is used to allow remote control of the panel, either via a SCADA system, or AT control system. 2.4.1.10 Input 52 Remote Start, when the set is switched to auto and Local Control Off/ Remote On the energising this input will start the generator, subsequent loss of this signal will then stop the machine. 2.4.1.11 Input 53 Manual/Auto Switch, this is the key switch input from the control panel that allows the user to run the machine fully automatically. 2.4.1.12 Input 54 Speed Increase, energising this input will increase the speed bias output from the GEMPAC, this is only possible if the Local Control is enabled. 2.4.1.13 Input 55 Speed decrease, energising this input will decrease the speed bias output from the GEMPAC, this is only possible if the Local Control is enabled.


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2.4.1.14 Input 56 Common negative for all digital inputs on Board 3 2.4.1.15 Relay 6 ECM Idle Rated Selector, closing this will indicate to the ECM wither the generator should run at idle speed or nominal speed, this can be selected automatically using the Starting Time, a time of 0 seconds means that the GEMPAC will not activate the relay at all. 2.4.1.16 Relay 7 Alarm Reset, this resets the alarms in the ECM 2.4.1.17 Relay 8 Close Air Flaps, this relay will energise the air flaps, when this close signal is returned or the engine speed drops below 30Hz then the relay will de-energise.

2.5

Slot #4, analogue output

Slot #4 is used for governor/AVR outputs. These outputs are active outputs i.e. they use the internal power supply. The outputs are galvanically separated from each other and the rest of the unit.

Term. 65 66 67 68 69 70 71 72

Function Not used +/-20 mA out 0 Not used Not used +/-20 mA out 0 Not used

Description Speed governor set-point output

AVR voltage set-point output

The current outputs can, if needed, be converted to voltage using a resistor across the terminals (200 # will convert the +/-20 mA into +/-4 VDC, for volts control), (10 # will convert the +/-20 mA into +/-0.2Vfor Barber Coleman Speed control with the Cummins ECM) For different governor control interface requirements please refer to Aggreko Manufacturing technical department for advise.


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2.6

Slot #5, AC measuring

Term. 73 74 75 76 77 78 79

Function I L1 s1 I L1 s2 I L2 s1 I L2 s2 I L3 s1 I L3 s2 U L1

80 81

U L2

82 83

U L3

84

U neutral

85 86 87 88 89

U L1 U L2 U L3

Technical data Generator current L1 Generator current L2 Generator current L3 Generator voltage L1 Not used Generator voltage L2 Not used Generator voltage L3 Generator voltage neutral Bus voltage L1 Not used Bus voltage L2 Not used Bus voltage L3

Ferrule CR CR2 CY3 CY2 CB CB2 GR3

Description 1/5 A AC input

Max. 690 VAC phase - phase value

GY3


GB3


GN2

For land-based applications only

LR2 LY2 LB2


1/5 A AC input 1/5 A AC input

Max. 690 VAC phase - phase value Max. 690 VAC phase - phase value

NOTE: Current inputs are galvanically separated. Maximum burden is 0.3 VA per phase. Voltage measurements are available in 4 levels: • • • •

100 to 110 VAC 200 to 240 VAC 380 to 480 VAC 660 to 690 VAC

The voltage level is to be defined when ordering, but can be changed onsite for the levels 1-3. The voltage level 4 (660 to 690 VAC) cannot be changed onsite, but must be defined when ordering. 2.7 Term. 90 91 92 93 94 95 96

Slot #6

Digital Inputs

Function Common Digital input Digital input Digital input Digital input Digital input Digital input

Description Digital Input Common Mode Selector 1 Mode Selector 2 Mode Selector 3 Volts Up Volts Down Mode Enable


Ferrule J2 K1048 K1050 K1052 K1038 K1040 K1036

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2.7.1

2.7.1.1

Description of Functions

Input 90

Board common (J2) 2.7.1.2

Input 91, 92 and 93

Mode Selectors see section 7, by selecting combinations of these inputs the GEMPAC will alter is control characteristics, e.g. Peak Lopping, Base Load, Load Sharing etc. Generally these are not wired into the panel controls, they can be utilised, if required, for external, remote hardwired control of the genset.

2.7.1.3

Input 94-95

Energising these inputs will instruct the GEMPAC to vary the voltage the voltage level accordingly, by changing the bias output on terminals 70 and 71 to the AVR. 2.7.1.4

Input 96

Mode Enable, this changes the control from Manual to automatic, all volts, speed, power and circuit breaker control are mode by the GEMPAC the logic is determined by the mode selection.


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2.8

Slot #7, Analogue and Engine Interface Card.

An engine interface board is mounted in slot #7. It consists of c onfigurable inputs and outputs. The configuration is done through the utility software and the default settings can be changed to the relevant settings. To configure the inputs, upload the parameter list from the multi-line 2 and select the input to be configured. Then a configuration dialog box appears and the settings can be changed. The standard title (e.g. 4-20mA in no. 1) can be changed, and the new title will also be shown in the display. The minimum and maximum values of the 4-20mA input can be adjusted: Value: Alarm value (e.g. 85°C) Min.: Value corresponding to 4mA (e.g. 0°C) Max: Value corresponding to 20mA (e.g. 100°C) The inverse proportional function is used when the input has inverse proportionality according to the measured value. This could for instance be when measuring a negative value. The inputs can be used as a high or low alarm. As a “high alarm” the alarm appears when the measured value is higher than the alarm limit, and as a “low alarm” the alarm appears when the measured values are lower than the alarm limit. The binary inputs use 24-volt constant signal. They are not pulse inputs. The inputs on the GEMPAC units are pre-configured to allow quick connection of a number of standard measurements, the analogue inputs are also re-configurable to allow changes to input type. These are not wired as standard on production generators. NOTE: The following I/O is for standard QSK45 configuration for other application types please refer to Appendix 1. Term. 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125

Function Analogue input Analogue input Analogue input Analogue input Analogue input Analogue input Analogue input Analogue input Pt100 Pt101 Pt102 Pt103 Pt104 Pt105 Tacho input Tacho input Digital input Digital input Digital input Digital input Digital input Common Relay 10 COM Relay 10 NO Relay 11 COM Relay 11 NO Relay 12 COM Com.

Description Air Inlet Pressure Left Air Inlet Pressure Left Air Inlet Pressure Right Air Inlet Pressure Right Exhaust Gas Temp Left Exhaust Gas Temp Left Exhaust Gas Temp Right Exhaust Gas Temp Right Air Temp Container Air Temp Container Air Temp Container Air Temp Control Panel Air Temp Control Panel Air Temp Control Panel Engine Speed Engine Speed Extern/intern set-point power Extern/intern set-point voltage Engine Stop Fan Fail Spare Common Speed Selection Speed Selection Engine Run Engine Run Engine Start/Crank


Ferrule S10 J2 S12 J2 110 111 112 113 104 105 106 107 108 109 MP1 MP2

FF J2 K725 K723 K705 K1062 K725

Page 22 of 88

2.8.1.1

Input 114

Extern/inter set-point power, when energised the unit will base its nominal power level on a percentage of a 0-10V input on terminal 40. 2.8.1.2

Input 115

Extern/inter set-point voltage, when energised the unit will base its nominal voltage level on a percentage of a 0-10V input on terminal 42. 2.8.1.3

Input 116

Engine Stop, when energised this will begin the engine stopping cycle; the genset will deload (if this is not possible then the breaker will open after a set period 30 seconds plus de-load time); the breaker will open; then the engine will run for the preset cooling time, default 5 minutes before stopping. 2.8.1.4

Input 117

Fan Fail, this will go high if the engine cooling fan circuit breaker trips. 2.8.1.5

Input 118

Spare 2.8.1.6

Input 119

Common for 114 to 118, (J2). 2.8.1.7

Relay 10

Speed Selection, this allows the GEMPAC to utilise the speed selection input of the ECM or other connected device this relay is closed when the Nominal Frequency is set above 55Hz and open when set below 55Hz. 2.8.1.8

Relay 11

Engine Run, this is the engine run control relay, will close when the engine is required to run, equivalent to the fuel control relay. 2.8.1.9

Relay 12

Engine Start/Crank Relay, required to start/crank the diesel generator starter motor.


Page 23 of 88

2.9

Slot #8, Spare inputs

This slot is not used. Term. 126 127 128 129 130 131 132 133

Function Spare Spare Spare Spare Spare Spare Spare Spare

Description Spare Spare Spare Spare Spare Spare Spare Spare


Ferrule

Page 24 of 88

3 3.1

Example Wiring Diagrams AC connections

(3-phases), see specific generator schematics for detailed connection details

3.1.1.1

Diagram 4 – AC Connections

NOTES: The neutral line (N) connection is not necessary for correct measurement. 3-phase without neutral is also possible. The current transformers ground connection can be on s1 or s2 connection, whichever is preferred. Fuses: 2A slow-blow.


Page 25 of 88

3.2

Load sharing lines

Even though screened cable is not needed, it is recommended if the cable run is longer than 5 m between units.

3.2.1.1

Diagram 5 – Load Sharing Line Connection

NOTE: If connecting to other types of loadsharing lines, e.g. Selco where only Active (kW) loadsharing is used then only terminals 38 (Common) and 37 (Active) need to be used, ensure that the correct Mode is selected. The other selectable types of load-sharer available are: ! ! ! ! !

GAC Selco T4800 Barber Coleman Woodward GAC


Page 26 of 88

3.3

Binary inputs

All binary inputs are 24 VDC bi-directional optocoupler. T ypical input is:

3.3.1.1

Diagram 6 – Binary input connections

The binary inputs use fixed signals. They do not use pulse signals. The GEMPAC will log when a signal is generated i.e. Engine Start and will begin the start cycle of the generator set.


Page 27 of 88

3.4

Analogue Inputs, External Set-points

The set-point inputs are passive, i.e. an external power source is needed. This can be an active output e.g. from a PLC, GEMPAC, Power Transducer, or a potentiometer can be used. 0…10 VDC input using potentiometer

GEMPAC

3.4.1.1

Diagram 7 - +10 V input using potentiometer

3.4.1.2

Diagram 8 - - +/-10 V input using potentiometer


Page 28 of 88

3.5

Optocoupler outputs for external counter

The kWh counter (terminals 20-22) and kvarh counter (terminals 21-22) outputs are lowpower outputs. For that reason the following circuit must be applied:

+ 24 VDC EXTERNAL COUNTER 0.5 uF 100V

GEMPAC PPU 20(kWh) 22 (COMMON) O VDC 3.5.1.1

Diagram 9 – Optocoupler Connections

This function is currently not utilised in GEMPAC.


Page 29 of 88

3.6

Display I/F cable

A standard computer extension cable can be used (9- pole SUB-D male/female plugs) or a cable can be tailored:

3.6.1.1

Diagram 10 – Diplay Cable 2

Wires min. 0.22 mm , max. cable length 6 m. Cable types: Belden 9540, BICC H8146, Brand Rex BE57540 or equivalent. A cable length up to 10 meters can be used.


Page 30 of 88

3.7

PC Interface Cable

A standard computer null-modem cable can be used (9- pole SUB-D female/female plugs) or a cable can be tailored:

3.7.1.1

Diagram 11 – Communications Cable


Page 31 of 88

4

Display unit

The display unit used in GEMPAC communicates and receives power supply via a 9-pole Sub-D plug. The plug fits directly onto the main unit, so the display can be mounted on the top of the main unit. If the display is to be used as remote display, a standard computer extension cable with male/female plug can be used for the connection.

4.1.1.1

Diagram 12 – GEMPAC Main Display

Display dimensions H x W x D = 115 x 220 x 20 mm.

4.2

Pushbutton functions

There are 10 pushbuttons on the display unit with the following functions: INFO: Shifts the display 3 lower lines to show the alarm list (up to 30 alarms can be in the list). JUMP: Enters a menu number selection. All settings have a specific number attached to them. Using the JUMP button enables the user to select and display any setting without navigating all the way through the menus (see later). VIEW: Shifts the upper line displaying. The following values can be shown: • • • • • • •

3 generator voltages (phase-to-phase) 3 bus voltages (phase-to-phase) 3 generator currents Generator power factor and produced power (kW) Generator apparent power (VA) and reactive power (kvar) Generator L1 frequency and voltage Bus L1 frequency and voltage


Page 32 of 88

LOG:

:

Shifts the display 3 lower lines to show the event and alarm list.

Moves the cursor left for manoeuvring in the menus.

: Increases the value of the selected setpoint (in the setting menus). In the daily use display it is used for scrolling the second line displaying of generator values. SEL: Is used to select the chosen function (underscored selection in the lower line of the display). : Decreases the value of the selected setpoint (in the setting menus). In the daily use display it is used for scrolling the second line displaying of generator values BACK: Jumps backwards one step in the menu (to previous display).

:

4.3

Moves the cursor right for manoeuvring in the menus.

Display functions

4.3.1

First line in display (daily use display functions)

The first line is used to display generator and bus values. Typically the line will show 2 or 3 different values at the same time. The following line values can be seen: • • • • • • •

Generator voltage L1 L2 L3 (VAC) Bus voltage L1 L2 L3 (VAC) Generator current L1 L2 L3 (A) Generator power factor and active power (kW) Generator apparent power (kVA) and reactive power (kvar) Generator L1 frequency (Hz) and voltage (VAC) Bus L1 frequency (Hz) and voltage (VAC)


Page 33 of 88

4.3.2

Second line in display (daily use display)

The second line is a service line where various values can be shown. Scrolling is done using the and keys. The values available are shown in the table below. Note analogue measurements will change for different generator applications. For generator: Voltage L1-N (VAC) Voltage L2-N (VAC) Voltage L3-N (VAC) Voltage L1-L2 (VAC) Voltage L2-L3 (VAC) Voltage L3-L1 (VAC) Voltage max. (VAC) Voltage min. (VAC) Current L1 (A) Current L2 (A) Current L3 (A) Frequency L1 (Hz) Frequency L2 (Hz) Frequency L3 (Hz) Active power (kW) Reactive power (kvar) Apparent power (kVA) Energy counter (kWh) Power factor Voltage angle between L1-L2 (deg.) Voltage angle between L2-L3 (deg.) Voltage angle between L3-L1 (deg.)

4.3.3

For bus: Voltage L1-N (VAC) Voltage L2-N (VAC) Voltage L3-N (VAC) Voltage L1-L2 (VAC) Voltage L2-L3 (VAC) Voltage L3-L1 (VAC) Voltage max. (VAC) Voltage min. (VAC) Frequency (Hz) Voltage angle between L1-L2 (deg.) Frequency deviation (df/dt) (Hz/sec.) Voltage angle between generator voltage and bus voltage (deg.) Power supply voltage (VDC)

For analogue input: Air Inlet Pressure Left Air Inlet Pressure Right Exhaust Gas Temp Left Exhaust Gas Temp Right Air Temp Container Air Temp Control Panel Engine Speed

Second line in display (menu system)

When entering the menu system, the second line in the display is used for information about which function (with function identifying number) is chosen. Using the 4.3.4

and

keys will scroll through the settings.

Second line in display (alarm and event list)

When selecting the alarm (and event) list, the second line will display the latest alarm/event. Using the 4.3.5

and

keys will scroll through the list.

Third line in display (daily use display)

The third line is an indication line. The third line contains an explanation for the lower line selection of set-up.


Page 34 of 88

4.3.6

Third line in display (parameter menu display)

In the parameter menu the third line indicates the present setting of the function in question, and, if changes are to be made, the max. and min. possible value for the setting. 4.3.7

Fourth line in display (parameter menu display)

When entering the parameter menus, the first (entry) display uses the fourth line to select a sub-function for the parameter. What the selections are depends on the function selected. 4.3.8

Fourth line in display (daily use display)

In the daily use display, the fourth line is the entry selection for the parameter menu. If “SEL” is pressed, the selection of menu indicated with an underscore will be entered. Choices are: • • • •

“PROT”, protection setup “CTRL”, controls setup “POWER”, power control setup “SYST”, system setup

The settings related to the setup can be seen in the paragraph “Menu overview” where the specific function numbers (related to the “JUMP” function) can be seen. Examples: For protective function the first entry shows the “Bus high volt 1” setting (provided the option is chosen). In this case the fourth line shows: • • • •

“LIM”, setting of switch point “DEL”, setting of time delay “FC”, selection of which Fail Class the function will activate “ACT”, activate/de-activate the function

For control functions the first entry shows the “Synchronisation” function. In this case the fourth line shows: • • • • • • • •

“fMax”, max. allowed positive frequency deviation when synchronising “fMin”, min. allowed negative frequency deviation when synchronising “Umax”, max. allowed voltage deviation (positive or negative) when synchronising “tCB”, closing time delay for generator circuit breaker For power setup the first entry shows the “Start next gen.” relay output (if the option is chosen). In this case the fourth line shows: “LIM”, setting of load dependent start output activation limit “DEL”, time delay for activating the relay “ACT”, activate/de-activate the function

NOTE: No relay selection is present. This is due to the fact that the function relates to a predetermined relay output on slot #3.


Page 35 of 88

For system setup the first entry shows the “Nominal settings”. In this case the fourth line shows: “F”, nominal frequency setting “P”, nominal generator power setting “I”, nominal generator current setting “U”, nominal generator voltage setting

• • • •

The above settings are used by the GEMPAC for control and protection settings.

4.4

Menu overview

The following is the menu structure when entering settings of the GEMPAC. If no entry has taken place before, the first display to appear is the password display. Enter the factory setting password to gain access to the menus. If no actions have been taken within 3 minutes, the password entry will be de-activated, and a new password entry will be needed. The menu overview is divided according to the daily use display selections in the fourth line (“PROT”, “CTRL”, “POWER”, “SYST”). 4.4.1

Jump functions

The “JUMP” pushbutton is used to enter an exact channel number, and all channels can be entered using this button. The following menus can only be reached using the “JUMP” pushbutton: Use the setting. • • • •

and

buttons to change the settings and the “SEL” button to store the new

Software Version: Service menu: Application menu: GEMPAC Application Menu:

Channel 6000 Channel 4980 Channel 6100 Channel 5000

Beware: Write down the new password. If you forget it, entering the menus will not be possible. 4.4.2

Navigating in the menus

The menu navigating starts from the daily use display fourth line and is carried out from there using the “SEL”, 4.4.3

,

,

,

and “BACK” pushbuttons.

Setup menu system

The following is an example, but all menus operate in the same manner. Starting from the daily use display fourth line, select the menu indicated with underscore: (Move the underscore with the

and


pushbuttons).

Page 36 of 88

PROT CTRL POWER SYST

1010 BUS high-volt 1 Set point 103.0 % LIM DEL OA OB ACT

1020 BUS high-volt 2 Set point 105.0 % LIM DEL OA OB ACT

First entry?

En ter passw. passw.

1999

ENTER

QSK45 High Ambient Testing, Dubai

1011 BUS high-volt 1 103.0 120.0 % 1 RESET SAVE

Increase Decrease

Increase Decrease Moves the selection

4.4.3.1

Diagram 13 – Menu Navigation


Page 37 of 88

5

Menu set-points

The following lists are in numerical order, i.e. the set points and timers appear according to the given number. NOTE: For the latest settings please refer to Appendix 1 5.1 5.1.1

Standard Protection Functions Mains/BUS Voltage

Voltage selections relate to nominal phase – to phase voltage No.

Setting

1010 1011 1012 1013 1014

BUS overvolt 1 BUS overvolt 1 BUS overvolt 1 BUS overvolt 1 BUS overvolt 1

No.

Setting

1020 1021 1022 1023 1024

BUS overvolt 2 BUS overvolt 2 BUS overvolt 2 BUS overvolt 2 BUS overvolt 2

No.

Setting

1030 1031 1032 1033 1034

BUS undervolt BUS undervolt BUS undervolt BUS undervolt BUS undervolt

No.

Setting

1040 1041 1042 1043 1044

BUS undervolt BUS undervolt BUS undervolt BUS undervolt BUS undervolt

1 1 1 1 1

2 2 2 2 2

Selection display Set point Time Fail Class Enable

Min setting 100.0% 0.1 s FC0 OFF

Max. setting 120.0% 100.0 s FC5 ON

Factory setting 106.0% 10.0 s FC0 ON














Page 38 of 88

5.1.2

Mains/BUS Frequency

Frequency settings relate to nominal frequency setting. No.

Setting

1050 1051 1052 1053 1054

BUS high freq. 1 BUS high freq. 1 BUS high freq. 1 BUS high freq. 1 BUS high freq. 1

No.

Setting

1060 1061 1062 1063 1064

BUS high freq. 2 BUS high freq. 2 BUS high freq. 2 BUS high freq. 2 BUS high freq. 2

No.

Setting

1070 1071 1072 1073 1074

BUS low freq. 1 BUS low freq. 1 BUS low freq. 1 BUS low freq. 1 BUS low freq. 1

No.

Setting

1080 1081 1082 1083 1084

BUS low freq. 2 BUS low freq. 2 BUS low freq. 2 BUS low freq. 2 BUS low freq. 2


















Page 39 of 88

5.1.3

Generator Voltage

No.

Setting

1310 1311 1312 1313 1314

Gen. high volt 1 Gen. high volt 1 Gen. high volt 1 Gen. high volt 1 Gen. high volt 1

No.

Setting

1320 1321 1322 1323 1324

Gen. high volt 2 Gen. high volt 2 Gen. high volt 2 Gen. high volt 2 Gen. high volt 2

Selection display Set-point Delay Fail Class Enable

Min. setting Max. setting 100.0% 120.0% 0.1 s 100.0 s FC0 FC5 OFF ON






Page 40 of 88

No.

Setting

1330 1331 1332 1333 1334

Gen. low volt 1 Gen. low volt 1 Gen. low volt 1 Gen. low volt 1 Gen. low volt 1

No.

Setting

1340 1341 1342 1343 1344

Gen. low volt 2 Gen. low volt 2 Gen. low volt 2 Gen. low volt 2 Gen. low volt 2

5.1.4



















Generator Frequency

No.

Setting

1350 1351 1352 1353 1354

Gen. high Gen. high Gen. high Gen. high Gen. high

No.

Setting

1360 1361 1362 1363 1364

Gen. high Gen. high Gen. high Gen. high Gen. high

No.

Setting

1370 1371 1372 1373 1374

Gen. low freq. 1 Gen. low freq. 1 Gen. low freq. 1 Gen. low freq. 1 Gen. low freq. 1

No.

Setting

1380 1381 1382 1383 1384

Gen. low freq. 2 Gen. low freq. 2 Gen. low freq. 2 Gen. low freq. 2 Gen. low freq. 2

freq. 1 freq. 1 freq. 1 freq. 1 freq. 1

freq. 2 freq. 2 freq. 2 freq. 2 freq. 2


Page 41 of 88

5.1.5

Generator Reverse Power

Reverse power settings relate to nominal power setting. No.

Setting

1090 1091 1092 1093 1094

Reverse power Reverse power Reverse power Reverse power Reverse power

5.1.6

Min. setting -50.0% 0.1 s FC0 OFF


Factory setting -5.0% 5.0 s FC5 ON

Selection display Set-point Time Fail Class Enable

Min. setting 50.0% 0.1 s FC0 OFF
















Generator Overcurrent

Settings relate to nominal generator current. No.

Setting

1100 1101 1102 1103 1104

Overcurrent 1 Overcurrent 1 Overcurrent 1 Overcurrent 1 Overcurrent 1

No.

Setting

1110 1111 1112 1113 1114

Overcurrent 2 Overcurrent 2 Overcurrent 2 Overcurrent 2 Overcurrent 2

5.1.7

Generator Overload

Settings relate to nominal power setting. No.

Setting

1160 1161 1162 1163 1164

Overload 1 Overload 1 Overload 1 Overload 1 Overload 1

No.

Setting

1170 1171 1172 1173 1174

Overload 2 Overload 2 Overload 2 Overload 2 Overload 2


Page 42 of 88

5.1.8

Generator Current Unbalance

Settings relate to nominal generator current. No.

Setting

1220 1221 1222 1223 1224

Current unbalance Current unbalance Current unbalance Current unbalance Current unbalance

5.1.9




Factory setting 30.0% 10.0 s FC5 OFF








Generator Voltage Unbalance

Settings relate to nominal generator voltage. No.

Setting

1230 1231 1232 1233 1234

Voltage unbalance Voltage unbalance Voltage unbalance Voltage unbalance Voltage unbalance


5.1.10 Generator Reactive Power Import (loss of excitation) Settings relate to nominal generator power value (kW). No.

Setting

1240 1241 1242 1243 1244

var import var import var import var import var import



5.1.11 Generator Reactive Power Export (overexcitation) Settings relate to nominal generator power value (kW). No.

Setting

1250 1251 1252 1253 1254

var export var export var export var export var export




Page 43 of 88

5.2

Analogue Inputs (4…20mA input)

The alarms for the analogue 4…20mA inputs are activated when the inputs exceeds the set points. In the tables below the minimum setting correspond to an input at 4mA and the maximum setting correspond to an input at 20mA. 5.2.1

Inlet Air Restriction Left

This input is placed at terminal 98, 99. No.

Setting

1510 1511 1512 1513 1514

Air In Rest LH1 Air In Rest LH1 Air In Rest LH1 Air In Rest LH1 Air In Rest LH1

No.

Setting

1520 1521 1522 1523 1524

Air In Rest LH2 Air In Rest LH2 Air In Rest LH2 Air In Rest LH2 Air In Rest LH2

5.2.2


Min setting 0 mbar 0.1 s FC0 OFF

Max. setting -60 mbar 10.0 s FC5 ON

Factory setting -45 mbar 1.0 s FC1 OFF













Inlet Air Restriction Right


Setting

1530 1531 1532 1533 1534

Air In Rest RH1 Air In Rest RH1 Air In Rest RH1 Air In Rest RH1 Air In Rest RH1

No.

Setting

1540 1541 1542 1543 1544

Air In Rest RH2 Air In Rest RH2 Air In Rest RH2 Air In Rest RH2 Air In Rest RH2


Page 44 of 88

5.2.3

Exhaust Gas Temperature Left


Setting

1550 1551 1552 1553 1554

Exh Temp Exh Temp Exh Temp Exh Temp Exh Temp

No.

Setting

1560 1561 1562 1563 1564


5.2.4

Left 1 Left 1 Left 1 Left 1 Left 1

Left 2 Left 2 Left 2 Left 2 Left 2


Min setting 0 °C 0.1 s FC0 OFF

Max. setting 750 °C 10.0 s FC5 ON

Factory setting 500 °C 1.0 s FC1 OFF













Exhaust Gas Temperature Right


Setting

1570 1571 1572 1573 1574


No.

Setting

1580 1581 1582 1583 1584


Right1 Right1 Right1 Right1 Right1

Right2 Right2 Right2 Right2 Right2


Page 45 of 88

5.2.5

4...20mA Input 1


Setting

1730 1731 1732 1733 1734

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA

No.

Setting

1740 1741 1742 1743 1744

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA

5.2.6

in No1 1 in No1 1 in No1 1 in No1 1 in No1 1



Min setting 4.0 mA 0.1 s FC0 OFF

Max. setting 20 mA 10.0 s FC5 ON

Factory setting 16 mA 1.0 s FC1 OFF
















4...20mA Input 2


Setting

1750 1751 1752 1753 1754

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA

No.

Setting

1760 1761 1762 1763 1764

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA

5.2.7



4...20mA Input 3


Setting

1770 1771 1772 1773 1774

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA




Page 46 of 88

No.

Setting

1780 1781 1782 1783 1784

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA

5.2.8














4...20mA Input 4


Setting

1790 1791 1792 1793 1794

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA

No.

Setting

1800 1801 1802 1803 1804

4..20mA 4..20mA 4..20mA 4..20mA 4..20mA




Page 47 of 88

5.3

Analogue Input (PT100 input)

The alarms for the PT100 inputs are activated when the inputs exceeds the set points. 5.3.1

Container Temperature

This input is placed at terminal 106, 107, 108. No.

Setting

1590 1551 1552 1553 1554

Container Temp1 Container Temp1 Container Temp1 Container Temp1 Container Temp1

No.

Setting

1600 1601 1602 1603 1604

Container Temp2 Container Temp2 Container Temp2 Container Temp2 Container Temp2

5.3.2


Min setting o 0 C 0.1 s FC0 OFF

Max. setting o 80 C 10.0 s FC5 ON

Factory setting o 50 C 1.0 s FC1 OFF













Panel Temperature

This input is placed at terminal 109, 110, 111 No.

Setting

1610 1611 1612 1613 1614

Panel Temp Panel Temp Panel Temp Panel Temp Panel Temp

No.

Setting

1620 1621 1622 1623 1624

Panel Temp Panel Temp Panel Temp Panel Temp Panel Temp

1 1 1 1 1

2 2 2 2 2


Page 48 of 88

5.4

Tacho Input

The tacho input can measure a frequency input from10Hz to 10kHz. The alarms for the tacho input are activated when the input exceeds the set points. 5.4.1

Engine Speed


Setting

1630 1631 1632 1633 1634

Engine Speed Engine Speed Engine Speed Engine Speed Engine Speed

No.

Setting

1640 1641 1642 1643 1644

Engine Speed Engine Speed Engine Speed Engine Speed Engine Speed

1 1 1 1 1

2 2 2 2 2


Min setting 0 rpm 0.1 s FC0 OFF

Max. setting 3000 rpm 10.0 s FC5 ON

Factory setting 2500 rpm 1.0 s FC1 OFF


Min setting 0 rpm 0.1 s FC0 OFF

Max. setting 3000 rpm 10.0 s FC5 ON

Factory setting 2500 rpm 1.0 s FC1 OFF


Page 49 of 88

5.5

Binary Input

The alarms for the binary inputs are activated when the inputs are activated. 5.5.1

Emergency Stop Energised

This binary input is active low, and placed at terminal 24, 28. No.

Setting

1650 1651 1652 1653

Emerg. Emerg. Emerg. Emerg.

5.5.2

Stop in Stop in Stop in Stop in

Selection display Time Fail Class Enable

Min setting 0.0 s FC0 OFF

Max. setting 10.0 s FC5 ON

Factory setting 0.0 s FC2 ON







ECM Warning

This binary input is active high, and placed at terminal 43, 56. No.

Setting

1660 1661 1662 1663

ECM Warning ECM Warning ECM Warning ECM Warning

5.5.3



ECM Shutdown


Setting

1670 1671 1672 1673

ECM Shutdown ECM Shutdown ECM Shutdown ECM Shutdown

5.5.4



Air Flaps Closed


Setting

1680 1681 1682 1683

Air flaps closed Air flaps closed Air flaps closed Air flaps closed




Page 50 of 88

5.5.5

AVR Over Voltage


Setting

1690 1691 1692 1693

AVR AVR AVR AVR

5.5.6

Overvoltage Overvoltage Overvoltage Overvoltage











Excitation Loss


Setting

1700 1701 1702 1703

Excitation Loss Excitation Loss Excitation Loss Excitation Loss

5.5.7

Fuel Spillage




Setting

1710 1711 1712 1713

Fuel Spillage Fuel Spillage Fuel Spillage Fuel Spillage

5.5.8



Fan Fail


Setting

1720 1721 1722 1723

Fan Fail Fan Fail Fan Fail Fan Fail




Page 51 of 88

6

Control Menu

6.1

Standard Control

6.1.1

Synchronisation

No.

Setting

2010 2011 2012 2013 2014

Synchronisation Synchronisation Synchronisation Synchronisation Synchronisation

6.1.2

Sync. Blackout

No.

Setting

2020 2021 2022 2023

Sync. blackout Sync. blackout Sync. blackout Sync. blackout

6.1.3

General Failure (Sync. Fail)

No.

Setting

2030 2031 2032

General failure General failure General failure

6.1.4

Power Ramp Down

Selection display Df max. Df min. DU max. Breaker delay

Selection display Df max. DU max. Enable

Selection display Delay Fail Class

Min. setting 0.0 Hz -0.5 Hz 2% 40 ms

Max. setting 0.5 Hz 0.5 Hz 10% 300 ms

Factory setting 0.3 Hz 0.0 Hz 5% 100 ms

Min. setting 0.0 Hz 2% OFF

Max. setting 5.0 Hz 10% ON

Factory setting 3.0 Hz 5% ON

Min. setting 0.0 s FC0

Max. setting 120.0 s FC5

Factory setting 60.0 s FC0

Min. setting 1.0%/s 1.0%

Max. setting 20.0%/s 20.0%

Factory setting 5.0%/s 5.0%

Power % settings relate to nominal generator power. No.

Setting

2080 2081 2082

Power ramp down Power ramp down Power ramp down

Selection display Speed Breaker open


Page 52 of 88

6.2

Gempac Control

6.2.1

Cooling Time

The cooling time is the time the engine is running at rated speed without load before it’s stopped. This is only used during normal stop of the engine and in Fail Class 1. No.

Setting

2200 Cooling Time 2201 Cooling Time

6.2.2

Selection display Timer

Min setting 0s

Max. setting 1200 s

Factory setting 300 s

Start Time

The start time is the time the engine is running at idle speed (Idle/Rated relay = ON) before it’s set to rated speed (Idle/Rated relay = OFF) during start up. When Start Time is set to 0 sec, the engine will not run at idle speed during start up. No.

Setting

2210 Start Time 2211 Start Time

Selection display Timer

6.2.3

Synchronisation type.

No.

Setting

2150 2151

Sync. type Sync. type

Selection display Sync. type

Min setting 0s

First setting Static sync.

Max. setting 600 s

Second setting Dynamic sync.

Factory setting 0s

Factory setting Dynamic sync.

If dynamic synchronisation is chosen, the next menu will be 2010. If static synchronisation is chosen, the next menu will be 2140. 6.2.3.1

Dynamic synchronisation

The setting of df max. and df min. decides whether the generator synchronises when running faster or slower than nominal frequency. The “dU max.” setting is related to nominal generator voltage. The “dU max.“ setting is +/nominal generator voltage. The multi-line 2 compensates for the breaker delay time when synchronising. No.

Setting

2010 2011 2012 2013 2014

Dynamic sync. Dynamic sync. Dynamic sync. Dynamic sync. Dynamic sync.

Min. setting Selection display Df max. Df min. DU max. Breaker relay

0.0 Hz -0.5 Hz 2% 40 ms

Max. setting 0.5 Hz 0.5 Hz 10% 300 ms

Factory setting 0.3 Hz 0.0 Hz 5% 50 ms

The synchronisation pulse is 400 ms.


Page 53 of 88

6.2.3.2

Static synchronisation

The phase gain and frequency gain are the control parameters used during static synchronisation. They both control the governor output. The phase controller will keep the angle between the generator voltage and the busbar voltage within the closing window. The frequency controller will keep the generator frequency and the busbar frequency at the same value. No.

Setting

2140 2141 2142 2143 2144

Static sync. Static sync. Static sync. Static sync. Static sync.

Selection display GB close time Closing window Phase gain Frequency gain

Min. setting

Max. setting

0.0 s 0.1 deg. 0% 0%

100.0 s 20.0 deg. 100% 100%

Factory setting 1.0 s 10.0 deg. 40% 40%

The synchronisation pulse is 400 ms.

6.2.3.3

Blackout closing of breaker

Settings are accepted limits (generator voltage and frequency) for closing the breaker. The “dU max.” setting is related to nominal generator voltage. No.

Setting

2020 2021 2022 2023

Sync. blackout Sync. blackout Sync. blackout Sync. blackout

Min. setting Selection display Df max. DU max. Enable

0.0 Hz 2% OFF

Max. setting 5.0 Hz 10% ON

Factory setting 3.0 Hz 5% ON

NOTE: If blackout closing of breaker is enabled on more than one unit, external precautions must be taken to avoid two or more generators closing on a black/dead busbar simultaneously.

6.2.4

General failure (sync. fail.)

The general failure covers: • • • • •

Synchronisation time Breaker ON/OFF feedback fail Generator voltage not established Generator frequency not established Phase sequence error

No.

Setting

2030 2031 2032 2033

General failure General failure General failure General failure

Min. setting Selection display Delay Relay output A Relay output B

30.0 s R0 (none) R0 (none)

Max. setting 300.0 s R4 (relay 4) R4 (relay 4)

Factory setting 60.0 s R2 (relay 2) R0 (none)

The general failure cannot be disabled.


Page 54 of 88

6.3

PI controller

The GEMPAC includes controllers for the different running modes. The controllers control the analogue outputs (slot #4). The basic principle of the controller is that a calculation is being executed every 5 * ON time (relay output) or 5 * integ. time (analogue output). The result of this calculation indicates whether the actual value (e.g. nominal frequency) is within the deadband. In that case there will be no changes on the output. If the actual value is differing from the deadband, the controller will cause an output signal change. The analogue signal will change depending on the gain factor and the deviation from the actual value to the desired value. The period the output signal changes will be up to 5 * integral time. After a period of 5 * ON time or 5 * integral tim e, a new calculation is carried out. From the table below it appears what controllers are active in the different running modes. Controllers: Controllers Freq. Power Fixed freq. Fixed power Droop P loadsharing Fixed voltage Fixed var Fixed PF Q loadsharing

Voltage

var

PF

Mix factor f/P mix U/var mix

X

X

X X X

X X X X X

X

X

Note: 1 -The mix factors are not controllers, but they indicate the influence of the two controllers in question. 2 – These correspond to the Mode Selection

Example: The generator is running in loadshare mode. The f/P mix factor is set to 50%. Now the frequency controller participates with 50% of the governor control, and the power controller participates with: 100 - 50 = 50%. When running in the generators, the relevant controller must be set in each desired running mode. (Fixed frequency mode set frequency controller). With the exception of the PF controller, the controllers are active in more running modes depending on the application. Regardless of that, the controller values will be the same. 6.3.1

Deadband (+/- value)

The controllers will find a value within the deadband area. If the actual value is within this area, the output signals will not change. When the calculation shows an actual value outside the deadband area, the output signals change again.

6.3.2

Gain factor

The gain factor indicates with what rate the analogue output signal will change. A higher gain factor will cause a faster regulation, but it might also cause the prime movers to hunt.


Page 55 of 88

6.3.3

ON-time

The output relay is active for a time of = K * ON time. K is depending on the deviation from nominal value. Diagrams: Analogue output and output activation time.

f = Generator frequency K = Constant The output signal changes: t = K x integral time [ms]

f = Generator frequency U = Analo ue out ut si nal

6.3.3.1

Diagram 14 – PI Controller Details

PI Controller

Dead band Nominal Speed

Actual Speed

Speed Bias

Proporational Gain 5 x On Time

6.3.3.2

Diagram 14A – PI Control Example


Page 56 of 88

6.3.4

Frequency controller

The ON/integral time is a combined setting. If relay speed control setting is used, the setting indicates the shortest relay ON time. If the speed control setting is analogue output, the setting is for the PI controller integral time. Frequency % settings relate to nominal generator frequency. No.

Setting

2050 2051 2052 2053 2054

Freq. control Freq. control Freq. control Freq. control Freq. control

Min. setting Selection display Droop Deadband Gain ON/integr. time


0.0% 0.2% 1 10 ms

Max. setting 10.0% 10.0% 100 3000 ms

Factory setting 4.0% 1.0% 40 100 ms

Page 57 of 88

6.3.5

Power controller

The ON/integral time is a combined setting. If relay speed control setting is used, the setting indicates the shortest relay ON time. If the speed control setting is analogue output (option), the setting is for the PI controller integral time. Power % settings relate to nominal generator power. No.

Setting

Min. setting

2060 2061 2062 2063

Power control Power control Power control Power control

6.3.6

Power ramp up

Selection display Deadband Gain ON/integr. time

0.2% 1 10 ms

Max. setting 10.0% 100 3000 ms

Factory setting 0.2% 40 100 ms

The delay point and time is the point where the generator stops ramping after closing of breaker to pre-heat the engine before commencing to take load. The time duration of the pint is determined by the delay time setting. If the delay function is not needed, set the time to 0. Power % settings relate to nominal generator power. No.

Setting

2070 2071 2072 2073

Power ramp Power ramp Power ramp Power ramp

6.3.7

Power ramp down

up up up up

Selection display Speed Delay point Delay time

Min. setting

Max. setting

1.0%/s 1% 0.0 s

20.0%/s 100% 180.0 s

Factory setting 2.0%/s 10% 10.0 s

The breaker open point is where a relay output (relay 4) is activated to open the generator breaker before reaching 0 kW. Power % settings relate to nominal generator power. No.

Setting

2080 2081 2082

Power ramp down Power ramp down Power ramp down

Selection display Speed Breaker open


Min. setting

Max. setting

1.0%/s 1%

20.0%/s 20%

Factory setting 10.0%/s 5%

Page 58 of 88

6.3.8

Power/frequency control mix factor

The mix factor determines the relation between frequency control and power control when running parallel with other generators (load sharing). The reason for the factor is that there is only one power/frequency load sharing line. Setting the factor to 100% selects power control only, setting it to 0% selects frequency control only. No.

Setting

Min. setting

2090 2091

P/f contr. mix P/f contr. mix

6.3.9

Voltage controller.

Selection display Mix factro

0%

Max. setting 100%

Factory setting 50%

Voltage deadband % settings relate to nominal generator voltage. No.

Setting

2100 2101 2102 2103

Voltage control Voltage control Voltage control Voltage control

Min. setting Selection display Deadband Gain ON/integr. time

0.0% 1 10 ms



6.3.10 VAR controller var deadband % settings relate to nominal generator power value, i.e. it is assumed that the generator var value is the same as the kW value. This is not correct, but the assumption is made for control purposes only. No.

Setting

2110 2111 2112 2113

var control var control var control var control


0.0% 1 10 ms



6.3.11 VAR/Voltage control mix factor The mix factor determines the relation between voltage control and var control when running parallel with other generators (load sharing). The reason for the factor is that there is only one var/voltage load sharing line. Setting the factor to 100% selects var control only; setting it to 0% selects voltage control only. No.

Setting

2120 2121

var/U contr. mix var/U contr. mix

Min. setting Selection display Mix factor


0%

Max. setting 100%

Factory setting 50%

Page 59 of 88

6.3.12 Power factor (PF) controller The ON/integral time is a combined setting. If relay PF control setting is used, the setting indicates the shortest relay ON time. If the PF control setting is analogue output (option), the setting is for the PI controller integral time. PF deadband is the zone (+/- value) around PF setting value where the relay output does not operate. The value is disregarded if analogue PF control output is used. No.

Setting

2130 2131 2132 2133

PF control PF control PF control PF control



0.00 1 10 ms

Max. setting 0.10 100 3000 ms

Factory setting 0.05 40 100 ms

Page 60 of 88

7

Power Menu

The power menu includes all the menus used for power management - peak lopping. 7.1

7.1.1

Peak Lopping

Mains power

The mains power set point is the maximum allowed imported power from mains in a peak lopping system. It’s possible to have two set points, a daytime- and a nighttime set point. The daytime period is set in menu 3020. The GEMPAC needs a 0...10VDC signal on terminal 40, 41 from a power transducer, measuring the imported power from mains. 0VDC at the transducer signal must correspond to 0.0MW-imported power from mains. 10VDC at the transducer signal must correspond to the transducer scale set point in menu 3013. No.

Setting

3010 3011 3012 3013

Mains Power Mains Power Mains Power Mains Power

7.1.2

Selection display Daytime Night time Transducer scale

Min setting 0.00 MW 0.00 MW 0.00 MW

Max. setting 9.99 MW 9.99 MW 9.99 MW

Factory setting 0.75 MW 1.00 MW 1.50 MW

Daytime Period

The start and stop for the daytime period are set with hours and minute. No.

Setting

3020 3021 3022 3023 3024

Daytime Period Daytime Period Daytime Period Daytime Period Daytime Period

Selection display Start Hour Start Minute Stop Hour Stop Minute


Min setting 0 0 0 0

Max. setting 23 59 23 59

Factory setting 8 0 16 0

Page 61 of 88

7.1.3

Start First Generator

This set point is used to start the first gen-set when no other gen-set in the peak lopping system are active. When the imported mains power exceeds XX% (menu 3031) of the mains power set point (menu 3011 or 3012), the first gen-set is started and synchronised to the busbar. The gen-set will run at fixed power according to the Base Load set-point in menu 3033, until the imported mains power reach mains power set-point. It’s always the available gen-set with the lowest communication ID that will be started. No.

Setting

3030 3031 3032 3033

Start First Start First Start First Start First

7.1.4

Generator Generator Generator Generator

Selection display Set Point Time Base Load

Min setting 20% 0.0 s 0%

Max. setting 100% 100.0 s 100%

Factory setting 80% 10.0 s 5%

Stop First Generator

This set point is used to stop the gen-set when only this gen-set in the peak lopping system is active. When the imported mains power goes below XX% of the mains power set point, the first genset is stopped. No.

Setting

3040 Stop First Generator 3041 Stop First Generator 3042 Stop First Generator

7.1.5

Selection display Set Point Time

Min setting 20% 0.0 s

Max. setting 80% 100.0 s

Factory setting 20% 30.0 s

Start Next Generator

This set point is used to start the next gen-set when one or more gen-set in the peak lopping system already are active. When the load at the other active gen-sets exceeds XX% of their nominal power, the next gen-set is started and synchronised to the busbar. The load above the mains set point is equally distributed to the active gen-sets in percent of the their nominal power. It’s always the available gen-set with the lowest communication ID that will be started. No.

Setting

3050 Start Next Generator 3051 Start Next Generator 3052 Start Next Generator






Page 62 of 88

7.1.6

Stop Next Generator

This set point is used to stop the next gen-set when more than one gen-set in the peak lopping system is active. When the load on the gen-sets goes below XX% of their nominal power and the other active gen-sets have enough available power to handle the load, the gen-set will deload and stop. It’s always the active gen-set that have been connected longest time to the busbar, that will be stopped. This time will be reset when the circuit breaker are opened, and is not the same as the run time in menu 4410. No.

Setting

3060 Stop Next Generator 3061 Stop Next Generator 3062 Stop Next Generator





If the Open Breaker Request input is activated when the gen-set is in peak lopping mode, the gen-set will switch to manual mode (fixed frequency, fixed voltage). The peak-lopping mode is activated again by activate the Mode Enable input.


Page 63 of 88

8

System Menu

8.1

Settings

8.1.1

Nominal settings

No.

Setting

4010 4011 4012 4013 4014

Nominal settings Nominal settings Nominal settings Nominal settings Nominal settings

8.1.2

Transformer

No.

Setting

4020 4021 4022 4023 4024

Transformer Transformer Transformer Transformer Transformer

8.1.3

Selection display Frequency Generator Power Generator current Generator volt

Min. setting 48.0 Hz 10 kW 0A 100 V

Max. setting 62.0 Hz 99 MW 9000 A 25000 V

Factory setting 60.0 Hz 1000 kW 1220 A 440 V

Selection display Volt prim Volt sec Current prim Current sec

Min. setting 100 V 100 V 5A 1A

Max. setting 25000 V 690 V 9000 A 5A

Factory setting 440 V 440 V 2000 A 5A

External Communication

The CAN-bus ID for the Gempac is set in this menu. No. 4050 4051 4052 4053

8.1.4

Setting Ext. Comm. Ext. Comm. Ext. Comm. Ext. Comm.

Selection display ID Alarm Enable

Min setting 1 OFF OFF

Max. setting 20 ON ON

Factory setting 1 ON ON

Auto Detection Run

When Auto Detection Run is enabled the following protection alarms will be disabled when the engine not is running. • • • • • • • •

Inlet Air Restriction Left Inlet Air Restriction Right Exhaust Gas Temperature Left Exhaust Gas Temperature Right 4…20mA input 1 – 4 Engine Speed DG Voltage Low DG Frequency Low


Page 64 of 88

The Auto Detection Run function will detect the engine as running when DG Voltage > 30% of Unom and DG frequency are > 30Hz. When the engine is detected as running the timer will be started. When the timer timeout the protection alarms are enabled. No.

Setting

4110 Auto det. Run 4111 Auto det. Run 4112 Auto det. Run

8.1.5

Selection display Time Enable

Min setting 0.0 s OFF

Max. setting 120.0 s ON

Factory setting 5.0 s ON

Min. setting 15.0 V 0.0 s FC0 OFF

Max. setting 25.0 V 10.0 s FC5 ON

Factory setting 18.0 V 1.0 s FC0 ON

Battery Low Voltage Alarm

No.

Setting

4220 4221 4222 4223 4224

Battery Battery Battery Battery Battery

low V low V low V low V low V



Page 65 of 88

8.1.6

Load Share Line Selection

The load sharing is selected to the type of load share unit connected to the load sharing line. Only one type of load share units can be connected to the load sharing lines. This load share line selection only select the voltage level on the load share line. The impedance must be adjusted externally. With Deif, Barber Coleman Woodward and GAC load sharing two load sharing lines are used, one for active (P) load sharing (term. 37, 38) and one for reactive (Q) load sharing (term. 38, 39). With Selco T4800 load sharing only one load share line is used for active (P) load sharing (term. 37, 38) and there is no voltage/var/power factor control. To fit the load share signal to the right Barber Coleman load share unit, it’s possible to configure the load share signal between 1 and 5VDC by menu 4240. No. 4250 4251

Setting Load sharing Load sharing

No. 0 1

Load share line Deif Selco T4800

2

Barber Coleman

3 4

Woodward GAC

Setting

Selection display DEIF Selco T4800 Barber Coleman Woodward GAC Active ± 5VDC ± 1VDC

Reactive ± 5VDC NA

±0-5VDC

±0-5VDC

0-3VDC 0-5VDC

0-3VDC 0-5VDC


0 1 2 3 4

Factory setting -

0

Comments -100%...0…+100% -100%…0…100%. Both f and P contribution to active load share -100%…0…100% Configurable signal range 0…100% 0…100%

Page 66 of 88

8.1.7

Tacho Input Configuration

When the tacho input not are used, the number of teeth must be set to 0. The readout will then be 0 RPM. Menu 4402, 4403, 4404 and 4405 are only available for Twinpack and 50G3 application. The cranking will stop when the engine reach “crank limit speed”. If the engine fails to start within “max crank time”, then will the cranking stop for the selected “rest time”, and the start cranking again. The number of cranking attempts is set in menu 4405. If the engine fails to start within the selected start attempts a start fail alarm will appear.

No. 4400 4401 4402 4403 4404 4405

8.1.8

Setting Tacho Config Tacho Config Tacho Config Tacho Config Tacho Config Tacho Config

Selection display Numb. of teeth Crank. Lim. Max Crank Time Rest. time Start Attempts

Min setting 0 0 RPM 0s 0s 1

Max. setting 500 6000 RPM 600.0 s 600.0 s 10

Factory setting 0 450 RPM 5.0 s 10.0 s 3

Total Running Time

The running time of the gen-set is the total time the generator fuel run relay has operated since the GEMPAC unit was installed. This menu is used for setting the running time of the gen-set at the time when the Gempac is mounted. No.

Setting

4410 4411 4412 4413 4414

Total Run Time Total Run Time Total Run Time Total Run Time Total Run Time

Selection display Years Days Hours Minutes


Min setting 0 0 0 0

Max. setting 40 364 23 59

Factory setting 0 0 0 0

Page 67 of 88

8.2

System setup

8.2.1

Nominal settings

No.

Setting

4010 4011 4012 4013 4014

Nominal settings Nominal settings Nominal settings Nominal settings Nominal settings

8.2.2

Transformer

Min. setting Selection display Frequency Generator power Generator current Generator volt.

48.0 Hz 10 kW 0A 100 V

Max. setting 62.0 Hz 99 MW 9000 A 25000 V

Factory setting 60.0 Hz 480 kW 787 A 440 V

Voltage transformer: If no voltage transformer is present, the primary and secondary side values are set to generator nominal value. No.

Setting

4020 4021 4022 4023 4024

Transformer Transformer Transformer Transformer Transformer

8.2.3

Controller settings

Min. setting Selection display Volt. prim. Volt. sec. Current prim. Current sec.

100 V 100 V 5A 1A

Max. setting 25000 V 690 V 9000 A 5A

Factory setting 440 V 440 V 1000 A 5A

The setting values are used if external set-point or serial communication set-point is not chosen. That means that the mode inputs (terminals 50 and 53) for external set-points are OFF. The GEMPAC unit will control the generator according to these set-points: Fixed power mode (48): Fixed var mode (51): Fixed PF mode (52):

Set-point 4031 Set-point 4032 Set-point 4033

Power setting relates to generator nominal power (kW). var setting is inductive reactive power and relates to generator nominal power (kW ~ var). Power factor setting is inductive value. No. Setting Min. setting Max. Factory setting setting 4030 Controller Selection display 4031 Controller Power 0% 100% 100% 4032 Controller var 0% 100% 30% 4033 Controller Power factor (ind.) 0.60 1.00 0.90


Page 68 of 88

Communication control enable/disable control (option H) No.

Setting

4040 4041 4042 4043 4044 4045 4046

Comm. control Comm. control Comm. control Comm. control Comm. control Comm. control Comm. control

Min. setting Selection display Power Frequency Voltage var PF Mode selections

OFF OFF OFF OFF OFF OFF

Max. setting ON ON ON ON ON ON

Factory setting OFF OFF OFF OFF OFF OFF

NOTE: Selecting communication control ON will overrule external and internal settings. 8.2.4

External communication control

No.

Setting

4050 4051 4052

External comm. External comm. External comm.

Min. setting Selection display ID 19200 Baud

1 OFF

Max. setting 247 ON

Factory setting 1 OFF

The Baud rate can only be changed with MODBUS communication. 8.2.5

External Communication Protection

No.

Setting

4090 4091 4092 4094

External comm. External comm. External comm. External comm.

8.2.6

Date and time (internal clock) setting

No.

Setting

4100 4101 4102 4103 4104 4105

Date and time Date and time Date and time Date and time Date and time Date and time

error error error error

Selection display Delay Fail Class Enable

Min. setting 1.0 s FC0 OFF


Factory setting 10.0 s FC0 OFF

Min. setting

Selection display Year Month Date Hour Minute


Max. Factory setting setting These settings have no practical limit. Factory settings will be present date and time in GMT –1 Hour when produced.

Page 69 of 88

8.2.7

Auto detection of running signal

This function inhibits the generator frequency and voltage alarms when the measurements are less than 30% of the nominal values. No.

Setting

4110

Auto detection run Auto detection run

4111

Min. setting Selection display

-

Max. setting -

Auto det. run

OFF

ON

OFF

Min. setting

Max. setting 24.0 V 10.0 s FC5 ON

Factory setting 18.0 V 1.0 s FC0 OFF

8.2.8

Battery under voltage alarm

No.

Setting

4220 4226 4227 4228 4225

Battery low V Battery low V Battery low V Battery low V Battery low V


15.0 V 0.0 s FC0 OFF

Factory setting -

The alarm is for the auxiliary power supply. 8.2.9

Language

No.

Setting

4230 4231

Language Language

Setting Selection display English German French Spanish

1 2 3 4

Factory setting 1 -

8.2.10 Number of teeth No.

Setting

4400 4401

Number of teeth Number of teeth

Min. setting Selection display Set-point

0

Max. setting 500

Factory setting 142

This setting is used for adapting the GEMPAC unit tacho signal to the number of teeth on the engine flywheel, if the tacho input on the I/O extension card is used. If zero is entered then the function will be disabled.


Page 70 of 88

8.2.11 User password The user password menu can only be entered using the “JUMP” pushbutton. No.

Setting

4976

User password

Min. setting Setting

0

Max. setting 32000

Factory setting 2000

8.2.12 Service menu The service menu can only be entered using the “JUMP” pushbutton. This menu is used in service situations. In the alarm selection you can see all the alarm timers and their remaining time if they are counting. The input and output selections show the present status of the inputs and outputs. E.g. mode inputs, relay outputs and load sharing lines. No. 4980

Setting Service menu Service menu Service menu Service menu

Description Selection display Alarm Digital input Digital output

Shows remaining time Shows input status Shows output status

8.2.13 Application menu This menu can only be entered using the “JUMP” pushbutton. The purpose of this menu is to change the measuring principle of the multi-line 2, if it is used in different distribution systems. No. 6100

Setting Application Application Application Application

Selection display Mode 0 Mode 1 Mode 2

Description Normal (3 phase) Split phase Single phase

Factory setting Normal (3 phase) -

The split phase selection is used if the distribution system is one with 2 phases and neutral. The phases are split 180 degrees. The display shows L1 and L3. The single phase selection is used in a system with one phase (L1) and neutral. The display shows only L1.


Page 71 of 88

8.2.14 Transferring set points by CAN-bus. To ensure that the settings of the GEMPAC’s in a peak lopping system are alike, the following settings are transferred by CAN-bus to the other GEMPAC’s. No. 1010 1020 1030 1040 1050 1060 1070 1080 2050 2060 2090 2100 2110 2120 2130 3010

Name UBBHigh1 UBBHigh2 UBBLow1 UBBLow2 fBBHigh1 fBBHigh2 fBBLow1 fBBLow2 Freq. Control Power Control P/f Control Mix Voltage Control VAR Control VAR/V Mix PF Control Mix Mains Power

Set point Set point Set point Set point Set point Set point Set point Set point Droop Deadband Mix Factor Deadband Deadband Mix Factor Deadband Daytime

Time Time Time Time Time Time Time Time Deadband Gain

Settings Fail-class Fail-class Fail-class Fail-class Fail-class Fail-class Fail-class Fail-class Gain Intg. Time

Gain Gain

Intg. Time Intg. Time

Gain Nighttime

3020

Daytime Period

Start Hour

3030

Start first generator Stop first generator Start next gen. Stop next generator Nom. Settings Date - Time Load share output Load share type

Set point

Start Minute Time

Intg. Time Transducer scale Stop Hour

Set point

Time

Set point Set point

Time Time

Frequency Year Max. Voltage Type

Voltage Month

3040 3050 3060 4010 4100 4240 4250


Enable Enable Enable Enable Enable Enable Enable Enable Intg. Time

Stop Minute

Base Load

Day

Hour

Minute

Page 72 of 88

9

Extern Communication Control

It’s possible to control the Gempac by the Modbus protocol via the Service Port. Referrer to “Modbus Protocol for Aggreko Gempac” by MAA / 020206. The input “Local Control On” (terminal 51) must be disabled to use the extern communication control, and enabled to use local control. When extern communication control is selected then the digital inputs ignored.

Terminal 91 92 93 96 48 52 53 50 114 115

Name Mode Selector 1 Mode Selector 2 Mode Selector 3 Mode Enable Engine Start Remote Start Manual / Auto switch Close CB Request Extern set-point Power Extern set-point Voltage


Page 73 of 88

10 Mode selection The following modes can be selected with mode input 1, 2, 3 and Mode Enable. Mode1-5 can be overruled by intern mode selection in menu 4260. No. Mode Enable Mode 3 Mode 2 Mode 1 Function Comments 0 0 X X X Manual No regulation 1 1 0 0 0 Peak looping Load / var sharing 2 1 0 0 1 Base load Fixed power / PF control 3 1 0 1 0 Droop Frequency droop / var sharing 4 1 0 1 1 Load sharing Load / var sharing 5 1 1 0 0 BaseLoad Fixed Power / var sharing 6 1 1 0 1 7 1 1 1 0 8 1 1 1 1 All mode changes are updated in the event log. Mode No. 0 1 1

Event text Manual Mode Peak Lopping Mode System Mode - Manual

1

System Mode - Load Share

1

System Mode - Base Load (P/PF) System Mode - Normal

1 2 3 4 5

Comments

If “Open Breaker Request” in peak lopping mode. If loss of mains (mains < 10kW) in peak lopping mode. If loss of CAN-bus connection in peak lopping mode. Returned to normal peak lopping mode after running in another system mode.

Base Load P/PF Mode Droop Mode Load Sharing Mode Base Load P/var Mode


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11 PEAK-LOPPING Peak lopping is a method of controlling a generator running in parallel with the mains. This method is intended for industries where fixed power consumption from mains is desirable (e.g. to cut off the very expensive peak of the power consumption). The way it is done is to measure and control the entire plant consumption and have this control decide how much power the parallel running generator must produce. A power transducer measures the actual imported po wer to the plant. A 0 to 10VDC signalline from the power meter controls the power output required by the GEMPAC power system. The GEMPAC/GEMPAC’s have a plant set point that will control the maximum allowable level of power import. By comparing the plant set point, the imported power and the generator loadsharing set points the GEMPAC system will start and stop the necessary gen-sets. The GEMPAC will always start the gen-set with the lowest running hours and stop the gen-set with the highest running hours. The can-bus is used to transfer start, stop and load-sharing signals between the generators. 11.1

Fault conditions

11.1.1 Loss of Mains When the mains are lost, the generators will run in load share mode and will use the load share line. 11.1.2 Loss of Can-bus Connection When an individual GEMPAC generator looses the can-bus connection, it will switch to fixed power / fixed PF mode and will continue to produce the same power and PF at the point when the loss of can-bus connection happened. The other gensets in the peak lopping system will continue to run in peak lopping mode. If there are only two GEMPAC generators in the peak lopping system, the one with highest ID will run fixed power / fixed PF and the one with lowest ID will run peak lopping. Power consumption MAINS

PLANT BUSBAR

0...10V

TAS-331DG or GPU

LOAD

CAN-BUS

11.1.2.1 Diagram 15 – Example Set-up


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11.2

Engine Deloading

The GEMPAC system has a deload function which is used when the generator breaker has to be opened with no load. The deload function is primarily used when running parallel with other generators or the mains. When running in stand-alone mode, it is not possible to deload the generator, as there is no other generator to take the load. If the deload input is set, the breaker will be opened instantly in fixed frequency mode. In base load, peak lopping, droop and loadsharing mode the speed of the generator will be decreased. The breaker will not open. When running in parallel, the deload input will still open the breaker instantly in fixed frequency mode. In base load, droop and loadsharing mode, the load will be decreased and the breaker will open at a configurable set point. The factory setting is 5% of nominal power.


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12 Utility Software With the utility software it’s possible to configure the spare analogue and binary inputs, and to set the control settings in all operation modes. The utility software must be version 1.21 or higher to work with Gempac software version 1.10.0 and higher.

12.1

Using the utility software.

Ensure that you have the latest version of the software available loaded on your PC. The utility software is a simple, powerful, widows driven interface tool for the GEMPAC unit. To connect to your PC, attach and RS232 null modem cable to the Service port of the GEMPAC unit and plug into a spare serial COM port on your PC. When you open the utility software select ‘Connection’ and tick the appropriate COM port from the menu. To upload the setting configuration from the unit Click ‘File’ ‘Upload Parameters’ it will take up to 30 seconds to upload the configuration list from the unit. To ensure all parameters are view Click ‘File’ ‘Filtration’ to deselect the filter. Selecting the relevant parameter, which opens an editing window to allow modification a number of parameters, can amend the parameter list. By clicking ‘View’ there are options for viewing real time analogue and digital information relating to the GEMPAC unit. This is particularly useful for troubleshooting wiring problems and identifying incorrectly connected controls and relays. Configuration files can be saved and printed out; it is recommended that prior to modifying the configuration of the GEMPAC unit a backup of the original be made. Entire configuration files can be downloaded to the GEMPAC unit Click ‘File’ ‘Download Parameters’ or individual parameters can be modified by Clicking ‘Send’ in the parameter edit window.

12.1.1 Application Control Note:

Do not run generator when updating the software revision When updating the software version of the GEMPAC unit, all parameters will return to the factory setting. The correct application will need to be chosen as well as all the correct parameters updated.

If a new software update is issued the operating system for the GEMPAC unit can be updated. The GEMPAC software is an a37 file extension. This should only be modified if advised by Aggreko Manufacturing. To update the software revision, ensure your PC is connected to the GEMPAC unit and click ‘File’ ‘Application Control’ When the application control menu appears select the Download


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sheet and ‘Open File’ find the revised a37 file in your harddrive and select then ‘Start Download’ this will take upto 5 minutes. When complete exit the window.

12.2

Configurable Spare Inputs

The 8 4…20mA analogue inputs and the two PT100 inputs (term. 98-111 and 126-133) can be configured in a dialog box like below. Besides setting the set-point, Timer, FailClass and Enable for each input the following can be set. • Input text • Minimum set-point value (only for 4..20mA inputs) • Maximum set-point value (only for 4..20mA inputs) • Unit (only for 4..20mA inputs) High / low alarm (alarm is activated when the value is over / below the set-point) • • Inverse Prop. (only for 4..20mA inputs)

Value Inverse Prop OFF Maximum set-point value

Minimum set-point value

Input 4 mA

20 m A

Value Inverse Prop ON Maximum set-po int value

Minimum set-po int value

Input 4 mA

20 m A

If an input has two alarm levels (like the analogue inputs), the input text, minimum set-point value, maximum set-point value, unit and the Inverse prop. setting will be the same for level 2 as for level 1. If the minimum set-point value and maximum set-point value are changed in level 1, it must be downloaded to the GEMPAC and then uploaded before it’s valid for level 2. If this is not done the messages “value is outside limits” or “illegal data value” will be shown.


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The binary input (term. 118) can be configured in a dialog box like below. Besides setting the set-point, Timer, FailClass and Enable for the input the following can be set. • Input text High / low alarm •

The configurable texts will only be shown in the protection menus and the utility software. The readout of the measuring value in line 2 of the display will always have a fixed text for the input.


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Input 4..20mA Analogue 4..20mA Analogue 4..20mA Analogue 4..20mA Analogue PT100 Input 1 PT100 Input 2 4..20mA Analogue 4..20mA Analogue 4..20mA Analogue 4..20mA Analogue

12.3

Input Input Input Input

E1 E2 E3 E4

Input Input Input Input

1 2 3 4

Terminals 98, 99 100, 101 102, 103 104, 105 106, 107, 108 109, 110, 111 132, 133 130, 131 128, 129 126, 127

Displayed text 4...20mA E1 4...20mA E2 4...20mA E3 4...20mA E4 PT100 1 PT100 2 4..20mA 1 4..20mA 2 4..20mA 3 4..20mA 4

Control settings libraries for operation mode

One control settings library is available for each operation mode. Mode No. 1 2 3 4 5

Mode Peak Lopping Base Load (P/PF) Droop Load Sharing Base Load (P/var)

Setting library name S1 S2 S3 S4 S5

When changing operation mode, the control settings library is automatic changed to the current operation mode. Each control setting library contains the following settings: • • • • • • • • • •

Frequency Control Gain Frequency Control Time Power Control Gain Power Control Time Voltage Control Gain Voltage Control Time var Control Gain var Control Time PF Control Gain PF Control Time


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With the utility software it’s possible to set the control settings for all settings libraries at the same time when downloading. With the menus at the display unit, it’s only possible to set the control settings for the current operation mode. When changing to Manual Mode (Mode Enable input = OFF) the displayed control setting in the display unit is from the last selected operation mode.


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13 System Logic This section describes the logic to be implemented in GEMPAC/GEMPAC for tripping and genset control. Fail classes are those actions that can be chosen from the GEMPAC/GEMPACs protection menus.

13.1 • • • • • • • • • •

13.2 •

Log Event CB Closed CB open Open breaker Request Close breaker Request Engine Start Engine Start remote Engine stopping Engine stopping remote Local/remote control Auto/Manual control

Engine Starting

If Start Engine (S9) AND S1==manual AND NOT ECM shutdown AND NOT C-Alarms o Log Event Open Air Flaps (Relay 8 OFF) o Open Fuel (Relay 2 OFF) o o Start Engine (Relay 11 and Relay 12 ON) o If Start delay > 0 s Idle Speed (Relay 6 ON) o Time out start delay (0 – 10 minutes) Rated Speed (Relay 6 OFF) Enable modes 0-9 !

! !

•

If Remote start(52) AND S1 == Auto AND NOT ECM shutdown AND NOT C-Alarms Log Event o Open Air Flaps (Relay 8 OFF) o o Open Fuel (Relay 2 OFF) Start Engine (Relay 11 and Relay 12 ON) o If Start delay > 0 s o Idle Speed (Relay 6 ON) Timeout start delay (0 – 10 minutes) o Rated Speed (Relay 6 OFF) • Enable modes 0-9 !

!


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13.3

Mode Initiate • o o o

•

13.4

if bRunning == ON AND Mode Enable ON Mode = input (91 - 93) Start sync Check for CB feedback on 25 and 26 if bRunning == OFF AND Mode Enable OFF Mode=0 o o start regulation (frequency/volt) if(close breaker) o start sync o o Check for CB feedback on 25 and 26

Warning - Fail Class 0 •

If Alarm o o

13.5 •

13.6 •

13.7 •

Log alarm Display Alarm

Engine Stop - Fail Class 1 If (NOT Remote Start AND S1==auto ) OR Engine Stop OR fail class 1 alarm. Log event o o Deload o Open CB (Relay 1 ON pulse) Check for CB feedback on 25 and 26 o o Timeout Cooling delay (0-10 minutes) o Engine stop (Relay 11 and Relay 12 OFF)

Emergency stop - Fail Class 2 If fail class 2 alarm o Log event Trip CB (Relay 3 OFF pulse) o Check for CB feedback on 25 and 26 o o Emergency stop / fuel close (Relay 2 OFF) Engine stop (Relay 11 and Relay 12 OFF) o Open CB (Relay 1 ON pulse) o

Shutdown - Fail Class 3 If fail class 3 alarm Log event o o Deload o Open CB (Relay 1 ON pulse) Check for CB feedback on 25 and 26 o o Engine stop (Relay 11 and Relay 12 OFF)


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13.8 •

13.9 •

Emergency shutdown - Fail Class 4 if fail class 4 alarm o Log event o Trip CB (Relay 3 OFF pulse) Check for CB feedback on 25 and 26 o o Close Air Flaps (Relay 8 On) o Emergency stop / fuel close (Relay 2 OFF) Engine stop (Relay 11 and Relay 12 OFF) o o Open CB (Relay 1 ON pulse)

Electrical Fault - Fail Class 5 if fail class 5 alarm Trip CB (Relay 3 OFF pulse) o o Open CB (Relay 1 ON pulse) Check for CB feedback on 25 and 26 o Display alarm o


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14 General data 14.1

Technical specifications

Accuracy:

Class 1.0 according to IEC 688

Operating temperature: -25…70°C Aux. supply:

24 VDC -25/+30%

Measuring voltage:

100…690 VAC. Consumption max. 0.15 VA per phase

Frequency:

30…70 Hz

Measuring current:

From current transformers …/1 A or …/5 A. Consumption max. 0.3 VA per phase

Binary inputs:

Input voltage 12…32 VDC. Impedance 2.4 k #, bi-directional

Open collector outputs: Supply voltage 12…32 VDC. Load max. 10 mA Load sharing lines: used.

+/-5 VDC, this s Scalable depending on the type of load sharing

Analogue inputs:

+/-10 VDC, impedance 100 k # (not galvanically separated)

Relay outputs:

250 V/8 A or 24 VDC/1 A. Refer to actual description of I/O’s

Safety:

To EN 61010-1 installation category (overvoltage category) III, 600 V, pollution degree 2

Galvanic separation:

Between AC voltage, AC current and other I/O’s: 3250 VAC – 50 Hz – 1 min. Between analogue outputs: 500 VDC – 1 min.

EMC/CE:

According to EN-50081-1/2, EN-50082-1/2, SS4361503 (PL4) and IEC 255-3

Material:

All plastic parts are self-extinguishing to UL94 (V1)

Climate:

HSE, to DIN 40040

Connections: stranded

4 mm multi stranded for AC currents, all others 2.5 mm multi

Response times:

From the set-point is reached till the output is activated and the delay set to 0. Busbar 2: Over/under voltage <50 ms Over/under frequency <50 ms Generator and busbar 1:Over/under voltage 70-150 ms Over/under frequency 70-150 ms Current: 100-160 ms Rocof: 100 ms (4 periods) Vector jump: 30 ms

2


2

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Protection:

Case: IP40 Terminals: IP20 Operator panel: IP52 (IP54 when mounted with gasket) To IEC 529 and EN 60529

Mounting:

Base mounted with six screws or DIN rail mounted.

Type approval: DNV, GL, LR and ABS for use in unmanned machinery space Mounting:

14.2

Base mounted with six screws or DIN rail mounted. If DIN rail mounted in marine applications, additional means against excessive mechanical vibrations must be used

Unit dimensions


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14.3

Display dimensions


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GEMPAC User Manual Version 3

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