AUTOMATIC STAND-BY AND PEAK-LOAD CONTROL

Transcription

1 KUHSE Operating Instructions Control Unit for Gen. Power Sets AUTOMATIC STAND-BY AND PEAK-LOAD CONTROL Type: KEA 071-SPL TA71SXXE.01 July 1996 (REPLACES 1994 EDITION) GENERAL DESCRIPTION AND APPLICATION Description is valid for Program No. 71-SPL, version 010 or higher. - Subject to be changed. - The Automatic unit KEA 071-SPL is designed to control stand-by and peak-load generating sets. Optionally, automatic synchronizer and automatic power control may be integrated. Functions of output relays and the relevant parameters are to be set by using a lap-top. In position AUTOMATIC, reconnections to mains supply, and in position TRIAL, change-overs from mains to generator supply and vice-versa are executed with overlapped synchronizing, without any interruption. The software for stand-by operation covers: Mains voltage failure sensing Control of preliminary start conditions Starting of prime mover on demand and change-over from mains to generator supply Frequency regulation for isolated generator set operation Generator set monitoring and protection Sensing of mains voltage restoration, synchronized overlap re-connection to mains supply and Cooling-down/shut-down of generator set. The software for peak-load operation is designed for: Starting of prime mover on demand and synchronizing the generator to mains voltage Power control of generator set Reducing the generator output, when peak-load operation shall be ceased To monitor the assembly and the generator set, the Automatic unit is fitted with following facilities: 3-phase voltage sensors, for mains and generator, monitoring under- and overvoltage, under- and overfrequency, and asymmetry 14 externally connected fault signals 4 internally connected fault signals each, for mains and generator voltage (DC) battery voltage sensor (not applicable, when program for sliding power value control, under peak-load conditions, is installed)

2 TA71SXXE / 96 CAUTION! This KEA unit shall be used only for purposes as announced in the written description Installation and commissioning of equipment shall be executed by qualified persons only Applicable rules, especially technical standards, as IEC or DIN VDE, have to be met strictly On setting the parameters, it has to be watched, that hazards to persons or equipment are absolutely excluded CONTENTS Design Page 3 Interconnections Page 4 Operating and indication elements Page 4 Operations and functions Page 5 Selector OFF/RESET Page 5 Selector HAND Page 5 Selector AUTOMATIC Page 6 Selector TRIAL Page 6 Push-button START Page 7 Push-button LAMPS TEST Page 7 Push-button ALARM OFF Page 7 Operate and fault indications Page 7 Controls on Page 7 Automatic device locked Page 7 Start indication Page 7 Overcrank / trouble Page 8 Mimic diagram /voltage sensing Page 8 Fault signals Page 9 Overspeed Page 10 Battery undervoltage Page 10 Fault signals No. 13 & 14 Page 10 Mains breaker failure / tripped Page 10 Generator overcurrent / Gen. CB tripped Page 11 No engine set shut-down Page 11 Synchronization failure Page Reverse power Page 11 Internal signals of volt. sensing Page Standard connections & programs Page 12 Start sequence Page 12 Operate or shut-down solenoid Page 12 Run-up detection Page 12 Genset s frequency control Page 13 Peak-load supply Page 13 Additional signal contacts Page 13 Emergency stop / emergency off Page 13 Integrated active power control (Optionally) Page 14 Integrated automatic synchronizer (Optionally) Page 15 Connections of relay unit RZ 071-D Page 15 Connections of analogue unit 17 Page Trouble shooting Page 18 Parametering Page 19 Technical data Page 23 Purchase ordering numbers Page 23 Dimensions / Connection diagram Page 24

3 TA71SXXE / 96 DESIGN The components: Automatic Generator set Control Unit KEA 071-SPL Relay Unit RZ 071-D, Relay Unit RZ 071-E, Plug-in Cable Connection Set, are needed to control stand-by and peak-load generator sets automatically. The Control Unit KEA 071-SPL is provided for flush mounting into control board's front, the Relay Units RZ 071-D and RZ 071-E are to be fixed on the mounting board inside the cubicle. Design of Control Unit KEA 071-SPL: Flush-mounting unit Protection degree (when installed): IP 44 Very compact design Circuitry in SMD mode Removable label strips for fault indicating and operating push-button elements Design of Relay Units RZ 071-D and RZ 071-E: printed circuit board flat unit, for fixing on mounting rail with snap-in fasteners for mounting rail in accordance with DIN EN Protection degree IP 00 The Relay Units RZ 071-D and RZ 071-E serve as interface modules between control functions of automatic unit KEA 071-SPL and switchgear assembly. They have provisions to be connected to DC Voltage supply from battery (changeable from 12 V to 24 V) Mains and generator circuit-breakers (or contactors) Cranking and shut-down means of prime mover Necessary control relays Up to 14 signal and fault circuits Voltage supply from charging dynamo (Input is fitted with automatic pre-excitation means for dynamo) The Relay Unit RZ 071-D includes, besides others: 10 relays, contacts rated for 6 A / 230 V or 30 V =, seven of these are suitable for parametering; 2 relays, contacts rated for 20 A / 30 V =, one of these is suitable for parametering; Multi-core plug-in connectors (Connection means to control unit KEA 071-SPL and to RZ071-E). The Relay Unit RZ 071-E contains: 14 coupling relays, which are suitable for parametering; 1 output relays for synchronizing pulse. The automatic control unit KEA 071-SPL includes an optical fiber connector, which permits data exchange with an optionally connected main control station (in some cases, a protocol transducer will be needed). When inserting an extra module, operating and fault conditions may be recorded. Furthermore, the automatic control unit could be parametered via optical fiber connector by a PC or laptop unit or, when connected to a telephone network, via MODEM. Thus, the following adjustments or indications (locked by pass-word protection) can be performed: Coding the fault signals for - alarm only or for shut-down conditions, - alarm sensing for open or closed circuits; - delayed or undelayed alarm conditions; - alarms with or without tripping the generator circuit breaker. Adjustment of response values for voltage and frequency sensing circuits and of values for delay and running times; Indicating of actual position of connected signal contacts; Indication of actual voltage, frequency and speed values and time settings.

4 TA71SXXE / 96 INTERCONNECTION IMPORTANT NOTE: The electrical connecting of control units KEA 071 and RZ 071 are to be made by experienced experts only! The Automatic Generator set Control Unit KEA 071-SPL has to be connected with Relay Unit RZ 071-D via plug-in connectors by means of the attached multi-core cables. The following signal wires have to be connected to the Automatic Unit KEA 071-SPL directly: Mains and generator voltage Battery voltage (in case the internal battery voltage sensor shall be used) Measuring output of actual generator power Measuring output of speed sensor (in case of using a tacho voltage generator or a pick-up) The supply voltage from battery, and all further signal wires have to be connected to the Relay Units RZ 071-D and RZ 071-E. The battery voltage input is fitted with a false connection barrier, however, the correct polarity has to be watched strictly; otherwise, some special electronic components could be damaged! The DC coils of relays, contactors, and of all other DC actuators shall be bridged by suppresser diodes or by other effective anti-interference protections. These measurements shall be executed also for relays connected to potential-free output contacts! Due to the fact, that a couple of relays may be specially predetermined for several functions, the printed status report, supplied with Automatic Unit KEA 071-SPL, is to be taken as valid only. Please note, that in case of a later replacement supply, only those modifications or parameters are incorporated, on which we received information. For a general connection diagram, please refer to page 25. In case of disconnecting the battery (for instance to replace the battery), prior to this, the battery charger has to be switched off! OPERATING AND INDICATING ELEMENTS Indication lights for basic functions Indication lights for fault signals (according to order) Indication lights for voltage and frequency monitoring Indication lights for fault signals (according to order) Push-button ON (I) for mains / generator Push-button OFF (0) for mains / generator Indication lights for signal circuit closed Push-button selector Push-buttons

5 TA71SXXE / 96 OPERATION AND FUNCTIONS The relevant indicating and operating elements are assembled, easy to survey, on the front plate of the Automatic Unit KEA 071-SPL. The operational modes are to be selected by means of four push-buttons, with integrated LEDs, showing the actual selected position. OPERATIONAL MODE: OFF On connecting the automatic unit to battery voltage, this operational mode position will be preselected automatically (Reset function), to prevent the generator set from starting unintentionally. On switching over from any other operational mode, the following will be initiated: Shut-down of generator set (if running); OPERATIONAL MODE: HAND On selecting this operational mode, a relay, which is configured for the function Auxiliary Drives ON, will be energized at once; the LED START INDICATION will show flashing light. There has to be a response signal, when engine start preparatory conditions are achieved. (Including, for instance: GAS LEAK PROOF TEST ENDED, WASTE GAS FLAP OPEN, LUB.-OIL PRES- SURE AVAILABLE.) After that, the LED START INDICATION will change to steady light, without engine running. If there is no requirement for any start preparatory conditions, a fixed jumper from L(-) potential to the input terminal for this signal (RZ 071-D) shall be connected. Now, the generator set may be started by pressing the push-button START. Under this operational mode, when pressing the Mains OFF push-button (O) in mimic diagram, the mains supply can be switched off (even when generator set is not running!); to re-close the mains supply, the Mains ON push-button (I) has to be pressed. Provided, voltage and frequency of generator are within its rated value limits, the load may be changed-over from mains to generator supply, by pressing the Generator ON (I) or Mains OFF (0) push-button, arranged in the mimic diagram. To re-connect the load to mains supply, the Mains ON push-button (I) has to be pressed. On Activating the push-button selection may be locked- out electrically by a wired jumper to terminals of the relay unit RZ 071-D (For example, by connecting a key-operated control switch); so an unintentional or unacceptable change of a decided selection will be avoided. By push-button selector, the following modes of operation are to be selected: Switching-off of all indicated fault signals (except fault signals No. 13 and 14, if external contacts should be still closed); Reset of automatic unit, if locked out (provided, the external EMERGENCY OFF contact is not closed). In case, mains voltage should be available, the mains supply (i.e. mains circuit-breaker or contactor) will be switched on in this selector position. pressing the Generator OFF (0) push-button, the generator circuit breaker will be opened, but the mains circuit breaker will not be closed. Reconnection to mains supply has to be made manually. All change-over movements are executed without synchronizing, that means, with interruption in supply. Should, in this case, a fault signal with shut-down function occur - or, for instance, the fault signal GENERATOR OVERCURRENT -, the generator breaker will be tripped, but the mains breaker will not be closed automatically. - On the other hand, no automatic change-over to generator supply will take place, if mains voltage should fail, while the generator set is running. The ON push-button will be inactive, if the corresponding supply voltage of the system, which should be switched on, is not within its pre-set values, or if the phase sequence of this system should be incorrect. A remote start demand signal does not initiate an automatic closing of the generator circuit breaker. To stop the generator set, the push-button selector is to be set to position OFF or (if no start demand signal is available) to position AUTOMATIC.

6 TA71SXXE / 96 OPERATIONAL MODE: AUTOMATIC When mains voltage is available, the mains supply is connected to load and the generator set is in automatic stand-by mode. The mains voltage will be measured and monitored permanently. As soon as the values for voltage or frequency are no longer within the adjusted limits, this condition will be indicated by the corresponding LED (f<, f>, U<, U>), arranged in the mimic diagram. After response time of sensing unit has elapsed (configurable), the start sequence program will be initiated. The start sequence program may be initiated, when mains voltage fails or when the connected remote start contact is closed, but also optionally, when mains voltage fails and the remote start contact is closed simultaneously. The latter function additionally has provisions for a start blocking. On initiating an automatic start, a relay, which is configured for the function Auxiliary Drives ON, will be energized at once; the LED START INDI- CATION will show flashing light. There has to be a response signal, when engine start preparatory conditions are achieved. (Including, for instance: GAS LEAK PROOF TEST ENDED, WASTE GAS FLAP OPEN, LUB.-OIL PRESSURE AVAILABLE.) After that, the LED START INDICATION will change to steady light, without engine running. If there is no requirement for any start preparatory conditions, a fixed jumper from L(-) potential to the input terminal for this signal (RZ 071-D) shall be connected. Now, the start sequence program will run and crank the engine. If the generator set should not start, even after complete cranking sequence program has elapsed, the fault signal OVERCRANK / TROUBLE will occur and the automatic unit will be locked out (Signal: AUTOMATIC DEVICE LOCKED). When the generator set, after running up, has reached rated voltage and frequency, the mains breaker will be switched off and the generator breaker will be closed, with a change-over interval of approximately 2 s (time value configurable). OPERATIONAL MODE: TRIAL On selecting this operational mode, a relay, which is configured for the function Auxiliary Drives ON, will be energized at once; the LED START INDI- CATION will show flashing light. After mains voltage has restored to normal values and re-connection delay has elapsed, the generator will be synchronized to mains voltage (provided, the automatic synchronizing is enabled to operate); after synchronizing, the generator circuit breaker will be switched off. In case the synchronized change-over is not required to operate (Terminal # 20 / Relay Unit RZ 071-D), re-connection to mains supply will take place with a switching interval. To prevent the engine from a heat increase, the generator set will run unloaded for the configured idle run time, and then it will be shut-down. The program also may be configured, that the start sequence will run when the mains breaker should be tripped by fault. (For switchboards in accordance with DIN VDE 0107 or DIN VDE 0108; otherwise available on demand.) The tripping of mains breaker will be indicated by a fault signal. After eliminating the fault, this indication has to be cancelled by pressing the push-button ALARM OFF. If the mains voltage is available, the re-connection to mains supply will be executed, after the pre-determined delay. Additionally, the start sequence program may be initiated by remote start demand signals for generator set operation with load transfer and generator set operation without load transfer. On remote start demand with load transfer, the generator set automatically will be started and synchronized to mains voltage, before mains circuit breaker will be opened (provided, mains voltage is available). When the remote start input is opened again, the re-connection of load from generator to mains supply also will be executed with a synchronized change-over. The input for remote start demand without load transfer is needed, for instance, when fire fighting pumps are connected. On activating this input, the generator set will be started, but the generator circuit breaker will not be closed automatically, while, in case of a mains voltage failure, the generator set will supply the load automatically. When engine start preparatory conditions are achieved, (conditions see under mode HAND), the LED START INDICATION will change to steady light and the start sequence program will be initiated.

7 TA71SXXE / 96 As soon as, after start of generator set, voltage and frequency of the generator are within the rated value limits, the load may be changed-over to generator supply, by pressing the generator breaker ON (I) or the mains breakers OFF (O) push-button, which are arranged in the mimic diagram. To change-over to mains supply, the generator breaker OFF (O) or the mains breaker ON (I) push-button has to be pressed. Change-over takes place with an overlap synchronizing or with an interruption, depending on signal to terminal # 20 of relay unit RZ 071-D. PUSH-BUTTON: START Only when operational mode HAND is selected, the starter motor can be energized and the engine can be cranked by pressing the push-button START. If the automatic unit s program is configured for a gas engine, this program sequence will run. Should a diesel engine need a pre-glowing PUSH-BUTTON: LAMPS TESTING On pressing this push-button, the indicating LEDs of KEA 071 front panel will be checked, without initiating or suppressing an actual alarm signal. PUSH-BUTTON: ALARM OFF By a pulse of this push-button, the audible signal caused by a fault signal, will be silenced. In case of mains failure during TRIAL operation, the load automatically will be changed-over to generator supply. It is not possible now, during mains voltage failure, to open the generator breaker by means of push-button. To stop the generator set, the push-button selector is to be set to position OFF or (if mains voltage is available) to position AUTOMATIC. procedure, this circuit has to be connected externally. When another operational mode is selected or when generator set is running, the push-button is not active. To include in this test further signal lights, assembled in switchboard cubicle, a relay of relay unit RZ 071-D has to be parametered and connected. After having eliminated the source of trouble, the visible signals may be switched off by pressing the push-button once again. OPERATE AND FAULT INDICATIONS The left-hand part of KEA front panel contains, arranged in two verticals, LEDs for indicating the CONTROLS ON After starting the generator set, this signal indicates the activating of monitoring circuits, which are depending on generator sets run. AUTOMATIC DEVICE LOCKED This indication shows, that an (external) EMER- GENCY STOP push-button has been pressed or that a faulty condition has caused the generator set to shut-down. The automatic control unit as well as the generator set is locked-out for any further starting attempt. START INDICATION This signal is lighting, if there is a starting demand, processed by the control unit, or if the operational mode HAND or TRIAL is selected. relevant operating and fault events. The following indications are provided as a basic fitting: The indication is switched off, as soon as the shutdown procedure is beginning. To reset the control unit, the push-button selector has to be set to position OFF(RESET). Prior to this, the reason for trouble has to be eliminated, or the EMERGENCY STOP push-button has to be unlocked. As long as there is no enable signal for starting, the LED is flashing. On start enable signal, the

8 TA71SXXE / 96 LED changes to steady light. OVERCRANK / TROUBLE This signal is switched on, if the generator set has not started, even after the complete start sequence program has elapsed (simultaneously with signal AUTOMATIC UNIT LOCKED), the generator set came to a standstill without The indication is switched off automatically, when the generator set s actual speed exceeds the ignition speed. Now, it is not possible, to actuate the starter motor, not even manually. any shut-down command emitted by the automatic control unit (with signal AUTOMATIC UNIT LOCKED), the generator set is still running even after complete stop time has elapsed (without signal AUTOMATIC UNIT LOCKED). MIMIC DIAGRAM / VOLTAGE SENSORS The mimic diagram symbolizes incoming mains and generator supply, circuit breakers and bus-bar system. Push-buttons are assembled for: Mains breaker ON (I) Mains breaker Off (0) Generator breaker ON (I) Generator breaker Off (0) The CLOSED position of circuit breakers is indicated by green LEDs, arranged below the corresponding push-buttons. The LEDs are flashing, as long as the synchronizing is active. There are four red and two green LEDs each for mains and generator voltage monitoring. They indicate normal conditions of each voltage system or the character of deviation from normal. The LEDs of first line, from left to right, are indicating: Underfrequency (f<) Voltage / frequency within normal range Overfrequency (f>) The second line of LEDs indicates: Undervoltage / incorrect phase sequence (U<) Voltage / frequency within normal range Overvoltage (U>) The signal UNDERVOLTAGE also will occur in case of wrong phase sequence or in case of a voltage vector asymmetry. For voltage monitoring, the following parameters may be entered: Undervoltage: Response and disengage value Overvoltage: Response and disengage value Underfrequency: Response and disengage value Overfrequency: Response and disengage value Limit values for asymmetry Response delay values for U< and f< Response delay values for U> and f> Disengage delay values Undervoltage with additional fault alarm signal Overvoltage with additional fault alarm signal Underfrequency with additional fault alarm signal Overfrequency with additional fault alarm signal Each monitoring criterion of mains and generator voltage sensors: Undervoltage, Overvoltage, Underfrequency, and Overfrequency, is configurable in such a manner, that: the output signal is not effective; the corresponding LED operates as a static indication for the voltage sensor output; the voltage sensor output is connected to an additional fault alarm. Static LED indication only The corresponding red LED is alight, when an enabled monitoring detects a deviation from normal value. During response delay, the green LEDs remain lighted, and they go out, when the delay has elapsed. The function now will be processed internally. When voltage or frequency values have recovered to pre-determined limits, the red LED goes out at once and a disengage delay time runs. The green LEDs are flashing, and they will change to a steady light, when the delay time has elapsed. In-

9 TA71SXXE / 96 ternally, now the voltage system is recognized as within normal limits. The generator s LEDs are out of order, when the operational mode OFF is selected, or when no start demand signal is available during AUTO- MATIC mode. LEDs for mains voltage system are operative permanently. LED indication along with fault signal When parametered for fault alarm signals in case of deviations from normal voltage or frequency values, the alarm will be given only after response delay time has elapsed. The green LEDs go out and the red LEDs operate as normal fault signal indicators, that means, they are flashing in case of a faulty condition, and the audible alarm will sound. As usual for all other fault signals, this signal triggers the general collective alarm output also. FAULT SIGNALS As a basic arrangement, the automatic control unit KEA 071-SPL is fitted with facilities to process 22 single fault indicating circuits, 4 of which are provided for monitoring of mains and generator voltages, 14 are freely determinable by the user. Basically, there are three groups of fault signal processing: 1. Operation dependent fault signals (for example LOW OIL PRESSURE) will be active only, when the generator set was started and an additional time lag has elapsed. Activation of these monitoring circuits is indicated by LED signal CONTROLS ON. 2. Operation independent fault signals (for example BATTERY UNDERVOLTAGE) are permanently active, except in case the push-button selector is set to position OFF. 3. The fault signals No. 13 and 14 are active, independent of generator set s operation and of selected operational mode. These monitoring circuits are used for permanently needed alarm information, even if the push-button selector should be set to position OFF (for example LEAKAGE). In position OFF, the audible signal will not be energized, but this signal triggers the general collective alarm output also. Any other operational mode (except OFF) causes usual processing of these fault signals. The fault signal processing may be configured, depending on the actual execution of circuitry, as follows: For signal contacts in NO (normally open) or in NC (normally closed) circuits; Delayed or undelayed operation dependent alarm; Signals effecting a warning only or an additional generator set shut-down; Additionally, for warning signals: - without generator breaker tripping; - with immediate generator breaker tripping; - with delayed (acc. idle run time) gen. breaker tripping, followed by generator set shutdown after idle running. The eight signals, which are internally used to monitor the mains and generator voltages, are: Mains undervoltage Mains overvoltage Mains underfrequency Mains overfrequency Generator undervoltage Generator overvoltage Generator underfrequency Generator overfrequency When using control contacts, the alarm will be released on contact closing (NO circuits) or on contact opening (NC circuits). With analog value inputs, the alarm condition is released, when the pre-set limit values will be passed. Each alarm will be indicated by the corresponding LED with flashing light and by audible alarm (for the configured duration). To silence the audible alarm, a pulse has to be given by push-button ALARM OFF; otherwise, the alarm will be switched off automatically (when parametered time has elapsed). On silencing the audible alarm, the LED signal changes to steady light. Several alarms, which could occur in sequence, would repeatedly release the audible alarm; each alarm is indicated by a separate LED. In case of warning alarms, another pulse by pushbutton ALARM OFF will cancel the visible signal, provided, the matter of alarm has been eliminated. In case of signals, which lead to a shut-down of generator set, any subsequent operation is locked out by the automatic control unit. This condition is shown by the LED signal AUTOMATIC DEVICE LOCKED. To reset the automatic control unit, after having eliminated the faulty condition (unlocking of an external EMERGENCY STOP push-button included), the push-button selector has to be set to

10 TA71SXXE / 96 position OFF (RESET). Now it is possible, to select again an operational mode. The fault signal indications from No 11 to No 14, when operating in NC circuits, are additionally configurable to actuate separate output relays. As long as the signal is not available, the corresponding relay is energized. The relay is switched off, when OVERSPEED To watch the overspeed condition, the generator frequency, or the frequency of a separate speed sensor (pick-up or tacho generator) has to be detected. When using the generator frequency, it is necessary to configure the fault signal GENERATOR UNDERVOLTAGE as a shut-down signal. This procedure makes sure, that in case of loss of generator voltage the engine set will be shutdown. For these signal circuits, the following parameters may be set: Limit speed for response; Disengaging value; No. of fault signal indication, which shall be coupled. BATTERY UNDERVOLTAGE This warning signal has to be parametered as being active, independent of engine run. To monitor this signal properly, the voltage supply for automatic control unit KEA 071-SPL has to be connected to another source than the monitored battery (see National Standard DIN VDE 0108/10.89, Part 1, Section , or comparable International Rules). This may be (as for example in large installations) a common control potential, supplied by several existing batteries, which are uncoupled by diodes. FAULT SIGNALS No. 13 & 14 The signal inputs No. 13 and 14 are capable to be retarded from 0 to 250 s. This means, the concerned switching contact has to remain at least for the pre-set time in the alarming position, before the signal will be monitored. the fault signal occurs or in case of a failure of power supply to the automatic unit. Regularly, the signal circuits will be shop-adjusted in accordance with customer s requirements. Nevertheless, all values may be entered or varied later, using a PC or a laptop. (For detailed information, please refer to the special instructions for parametering and configurating.) The input of relay unit RZ 071-D, corresponding with this signal, will be compared also. So it is possible, to connect an additional overspeed contact (for example a mechanical speed switch) to this input terminal. Each configured OVERSPEED alarm leads to a shut-down of engine set, even in case of parametering all signal circuits for warning only (This could be, for example, when prepared for supplying fire fighting pumps). When exceptionally the connected external speed contact shall initiate the OVERSPEED signal, but also cause a shut-down when supplying fire fighting pumps, the internal signal has to be configured to the corresponding fault signal indication No. The response speed values, however, have to be configured in a way, that they will not be exceeded. For monitoring the battery voltage, additionally an integrated battery voltage sensor may be configured upon request (not applicable, when program for sliding power value control, under peak-load conditions, is installed). The following values are configurable: Response value, Disengage value, Delay time, No. of fault signal indication, which shall be coupled. A separate relay may be configured to the voltage monitor output (NC circuit), effecting an NC alarm signal transmitting, even in OFF mode. Additionally, these signals are active also (but without audible alarm), when mode selector is in OFF position. This feature could be necessary, when tank overfilling or leakage shall be observed at any time. INTERNAL SIGNAL: MAINS CIRCUIT BREAKER FAILURE

11 TA71SXXE / 96 This fault signal is provided to indicate, that mains breaker has opened without receiving a tripping signal from automatic control unit (for example, when tripped by a circuit breaker assembled overcurrent release). To configure this signal circuit (necessary to meet the requirements of National Standards DIN VDE 0107 or DIN VDE 0108), a valid signal indication number has to be entered. The signal is additionally initiating the automatic start sequence program. The generator set will supply the load, as in case of mains voltage failure. This signal is processed internally, when, after emitting a closing pulse for circuit breaker (or contactor), the response signal for breaker position CLOSED is not available within a certain time. The pulse time for a contactor or breaker closing command therefore has to be parametered to a reasonable time (for example, 2 s). The corresponding input of relay unit RZ 071-D, however, will be also active. This input could be used, for example, to connect a control contact of an additional overcurrent relay, which can operate in a logical OR function. INTERNAL SIGNAL: GENERATOR CIRCUIT BREAKER FAILURE This fault signal is provided to indicate, that generator breaker has opened without receiving a tripping signal from automatic control unit (for example, when tripped by a circuit breaker assembled overcurrent release). To configure this signal circuit, a valid signal indication number has to be entered. This fault signal has to be configured for WARNING / SHUT-DOWN. This signal is processed internally, when, after emitting a closing pulse for circuit breaker (or contactor), the response signal for breaker position CLOSED is not available within a certain time. The pulse time for a contactor or breaker closing command therefore has to be parametered to a reasonable time (for example, 2 s). The corresponding input of relay unit RZ 071-D, however, will be also active. This input could be used, for example, to connect a control contact of an additional overcurrent relay, which can operate in a logical OR function. INTERNAL SIGNAL: NO ENGINE SHUT-DOWN When the ENGINE RUNNING signal is still available, even after shut-down time has elapsed, the fault signal indication OVERCRANK / TROUBLE will be initiated. This alarm would occur, for example, when a burned shut-down solenoid or a defective gas valve would prevent the engine from stopping. INTERNAL SIGNAL: SYNCHRONIZATION FAILURE On the event of activating the automatic synchronizer, a timer will be started. When the configured time has elapsed, the fault signal indication SYN- CHRONIZATION FAILURE occurs. For this signal indication, the following parameters may be entered: Delay time for alarm; No. of fault signal indication, which shall be coupled. INTERNAL SIGNAL: REVERSE POWER In case of a defective engine, when running in parallel, the generator breaker has to be switched off. An engine s malfunction will cause a reverse active power, verified by generator active power transducer, connected to measuring input terminal 8. For signal indication REVERSE POWER, the following parameters may be entered: Reverse power response value; Delay time for alarm; No. of fault signal indication, which shall be coupled. The active power transducer shall supply an output signal of: 0 / 4 / 20 ma = -25 / 0 / +100 % of generator output. INTERNAL SIGNALS OF VOLTAGE MONITORING Deviations of normal frequency or voltage values are allowed to be indicated as fault signals. When parametered for fault alarm signals, the alarm will be given only after response delay time has elapsed. The green LEDs go out and the red LEDs operate as normal fault signal indicators, that means, they are flashing in case of a faulty condition, and the audible alarm will sound. As usual for

12 TA71SXXE / 96 all other fault signals, this signal triggers the general collective alarm output also. When voltage or frequency deviations are configured as fault signal indications, the following parameters (as usual for other signals) have to be entered: Delayed or undelayed signaling; Warning alarm only or shut-down; Signal with or without generator breaker tripping. A fault signal indication is not influencing the voltage monitoring; that means for instance, the warning indication GENERATOR UNDERFRE- QUENCY, once initiated, will not be cancelled, when frequency has returned to normal. However, the correct frequency will be known by the automatic unit s program. STANDARD CONNECTIONS / PROGRAM SEQUENCES The normal models of KUHSE Automatic Control Units KEA 071-SPL are shop-configured as normal in accordance with parameter list (see page 19), unless otherwise specified according to customer s orders. START PROGRAM SEQUENCE The program is shop-configured for diesel or for gas engine, according to order requirements. The start sequence for gas engines is the following: Starter motor ON; (2 s after exceeding ignition speed:) Ignition ON; (2 s after ignition ON:) Gas valve OPENED; (In case of no start, another 7 s later:) Gas valve CLOSED and Starter motor OFF; (after 6 s:) Ignition OFF; (1 s later:) Another start sequence. The following parameters are provided for a start / stop sequence: Start delay; Cranking time; Time delay between Starter ON and Ignition ON ; Time delay between Ignition ON and gas flow; Interval; Nevertheless, all parameters are changeable or may be entered additionally, even after installation of switchboard. To realize this, a PC or laptop has to be connected to the assembled optical fiber connector. For more details, please refer to special instruction for coding and adjusting. Delay time for CONTROLS ON ; Delay for circuit breaker OFF; Idle running time; Shut-down time; Number of cranking attempts; Speed detecting by tacho generator; Speed detecting by pick-up; RUNNING signal via charging dynamo ( D+ ); RUNNING signal by generator voltage; Pick-up / tacho generator frequency at rated speed; Starter speed, disengage value; Ignition speed, disengage value; Rated speed, disengage value. In case of using diesel engines, which require a pre-glowing period to start, an external push-button for pre-glowing has to be provided, operative in selected mode HAND. For an automatic start sequence, the pre-glowing time is configurable (Start delay time). OPERATE -, SHUT-DOWN SOLENOID; ELECTROMAGNETIC GAS VALVE The normal way of configuring the shut-down solenoid is NO condition; that means, the solenoid will be energized (for an adjusted time) to shut-down the generator set. The solenoid remains energized, until generator set has reached standstill position. In case, the engine is fitted with an operate solenoid, which is de-energized to shut-down the generator set, the control mode for relay -K1 (Relay Unit RZ 071-D) has to be changed. This is not permitted, if switchboard and control circuitry have to meet the requirements of German Standard DIN VDE 0107! In case of using gas engines, the relay -K1 is configurable for the function GAS VALVE OPEN. When two relays are required to be installed in the gas safety path, another relay may be configured in like manner.

13 TA71SXXE / 96 DETECTION OF ENGINE RUNNING CONDITION The correct point of exceeding the engine s ignition speed for switching off the starter motor has to be sensed doubtless. For this reason, the automatic control unit KEA 071-SPL is regularly fitted with separate inputs for charging dynamo, tacho generator and for pick-up connection. The wiring for pick-up or for tacho generator connection has to be executed in shielded cables. In case of governing gas engines, it is absolutely necessary, to provide a pick-up, or a tacho generator with frequency signal output. The input for charger dynamo has provisions for an initial excitation of the dynamo, so AC charging generators may be used also without problems. The initial excitation will be switched off simultaneously with starter motor. The tumbler switch, arranged at the rear side of automatic unit KEA 071-SPL, has to be set in accordance with connected equipment: Lever in left position ( ): Pick-up Lever in right position ( ): Tacho generator For safety reasons, the program of automatic control unit KEA 071-SPL has facilities to detect the generator voltage also; so, an unintended engaging of starter during engine run is avoided. FREQUENCY CONTROL DURING ISOLATED GENERATOR SET OPERATION When the generator set substitutes the mains power, the generator set s frequency may be controlled to a rated value, independent of actual load. Therefore, the engine shall have provisions for remote speed control, or an electronic governor, fitted with control input, has to be assembled. The following parameters are configurable: Frequency maximum value; Frequency minimum value; Pulse length for governor; Interval between pulses. The automatic unit emits adjusting pulses to the engine s governor, when frequency is not within parametered limits. The interval between two pulses, for enabling the engine to react, is also configurable. PEAK LOAD SUPPLY When operational mode AUTOMATIC is selected, the generator set will be started on a peak load demand signal. After normal running conditions have been attained, the generator set will be synchronized to mains voltage. When running in parallel, the internal output power control (optional assembly) will be ready to charge the generator set. For a functional description of internal output power controller (optional assembly), please refer to next page. The configuring permits to run the generator set with a (parametered) constant output, or to control the output power by an external signal (for example, by a signal from a main control station), or by a manually adjusted set value (for example, by means of a separately arranged rheostat). When the peak load demand signal is cancelled, the generator set will be unloaded to approximately FURTHER SIGNAL CONTACTS For further switchboard control applications (signal lamp test, manual operations, or in like manner), several relays are configurable. These special Please note, that the interval and pulse times for frequency control are the same as for frequency matching during synchronizing. 10% of rated load, before the generator breaker will open. In case the internal output power control will not be applied, there are control inputs and outputs provided to connect an external power control unit. Mains voltage failures during peak load supply shall be monitored by special equipment, for example by a KNAE 9408 unit. This device will trip the mains breaker directly, so the generator set alone will continue to supply the load. When mains voltage has returned to normal conditions and after a re-connection delay, the generator set will be synchronized to mains voltage. When the peak load demand signal is available, the generator set again will run in parallel with mains supply; if not, the generator breaker opens and the generator set will shut-down after idle running time has elapsed. functions are shop-configured on demand, but the function mode may be changed also later without any problem.

14 TA71SXXE / 96 The declared current ratings of relay contacts shall not be exceeded! Each electric coil, connected to control outputs, shall have antiinterference protection! EMERGENCY STOP / EMERGENCY OFF (EXTERNAL) The Relay Unit RZ 071-D is fitted with a terminal No. 19, to connect EMERGENCY STOP pushbuttons. Only one short pulse is needed to initiate the EMERGENCY STOP procedure. Independent of actual operational mode, the following functions will be activated: Tripping of generator breaker; Shut-down of generator set; Locking-out of control unit for any further start attempt (Indication: AUTOMATIC DEVICE LOCKED). NOTICE: When installing the switchboard wiring, an additionally wired direct connection to the engine set's shut-down equipment shall be provided, overriding the computer controlled EMERGENCY STOP function. To perform a complete EMERGENCY OFF function, not only the terminal No. 19 of Relay Unit RZ 071 for EMERGENCY STOP has to be connected, but it has to be made sure also, that the mains breaker will be tripped on receiving this command. INTEGRATED OUTPUT POWER CONTROLLER (OPTIONALLY) The output power controller (assembled optionally, on demand) is configurable to act as a constant power value controller, or as a sliding power value controller. The generator set, running in parallel with mains, will be charged with parametered load (constant power value controller), or with a load corresponding to the set value of measuring input, terminal 7 (sliding power value controller). The power control system is active only, when operational mode AUTOMATIC or TRIAL is selected. When the two-level action of power controller is not activated, an external controller has to be provided. Suitable relays for connecting an external controller are configurable. The actual generator output value has to be connected as active power transducer signal to measuring terminal 8. The active power transducer shall supply an output signal of 0 / 4 / 20 ma, corresponding to -25 / 0 / +100 % of generator output. The signal range from 0 to 4 ma (according to -25 to 0 % of generator output) is required to monitor REVERSE POWER. All installed measuring current loops shall be potential-free. The output signal of 4-20 ma corresponds with declared power value of measuring transducer, but not with a percentage of generator s output power. This is important to be considered, when operating as sliding power value controller. When connected to a main control station, the value of 100 % generator output has to be calculated. The measuring input, of course, then shall not be used for monitoring the battery voltage. The power controller is acting in a two-level mode. The following parameters may be entered: Internal controller activated or not activated; Constant power or sliding power value control; Measuring range of active power transducer; Rated power of generator set; Nominal power for constant power control; Hysteresis of power controller; Response value for REVERSE POWER; Alarm delay for REVERSE POWER; Fault signal for REVERSE POWER; Pulse duration for speed adjusting; Intervals for generator loading; Interval at final control value; Monitoring delay for generator unloading. The generator set will be charged gradually, after having been coupled to run parallel with mains supply. For a weak load transfer, the time value of intervals for generator loading has to be chosen of suitable duration. When the range limits of parametered output power once have been attained, another (shorter) interval between adjusting pulses will become ef-

15 TA71SXXE / 96 fective, so the controller will be capable to react rapidly to a deviation from set value. On ending the peak load supply, the generator set will be unloaded gradually. When actual value falls below 10 % of generator rated output, the generator circuit breaker will be opened. At the same time, the input for signal UNLOADED will be monitored. In case a L(-) potential is available, the generator breaker also will be tripped immediately. On the event of activating the generator s unloading, a timer will be started. When the configured time has elapsed, without any unloading, probably the speed control circuit may be faulty, and the generator breaker also will be tripped, independent of actual load. In case of performing an external power controller, the signal UNLOADED has to be led to relay unit input. INTEGRATED AUTOMATIC SYNCHRONIZER (OPTIONALLY) The internal automatic synchronizer (assembled optionally, on demand) is acting as a singlechannel device, on which the closing time of circuit breaker is configurable. Because the measuring voltage is only single phase connected, for safety reasons a check synchronizer should be installed, as a second channel device. When monitoring the duration of synchronizing procedure, a fault signal may be initiated on exceeding the time. It is configurable, whether the change-over of load shall be executed with an interruption, or the automatic synchronizing procedure shall continue to act. The following parameters may be entered: Automatic synchronizer activated or not activated; Permitted difference frequency; Permitted difference voltage; Closing time of circuit breaker (or contactor); Fault signal delay for SYNCHR. FAILURE; No. of fault signal indication, which shall be coupled; Pulse length for frequency matching; Interval between pulses. The difference frequency is adjustable within a range of 0.1 to 0.4 Hz, and the breaker s closing time within a range of 40 to 140 ms (in steps of 20 ms). The recommended settings are: Difference frequency: Hz; Difference voltage: 10 % of rated voltage. When operating generating sets with large rotating masses, it is recommended to equip the automatic synchronizer, type KSY 11. When activated, the automatic synchronizer will check, whether the difference frequency is within the permitted limits or not. If not, an adequate pulse to the speed governor will be emitted, followed by an interval, enabling the engine set to react. During the interval, the synchronizing action is restrained. When the difference frequency should be less than 0.08 Hz, an output signal for SPEEDING UP will be emitted. The difference voltage also will be checked. In case of deviations being out of permissible limits, the synchronizing will be locked out. On full compliance of parameters, the breaker closing pulse will be emitted with an advance time (which equals closing time) before the moment of synchronism. The closing pulse has double length of closing time.

16 TA71SXXE / 96 CONNECTIONS OF RELAY UNIT RZ 071-D The control switches, connected to terminals 1 to 28, shall be connected to L(-) potential. Terminal 29 is provided to be connected to terminal D+ of charging dynamo. The relay unit contains features for an initial excitation of charging dynamo. The functions of several relays may be different, according to special configuring. Therefore, the individual printed status report is valid only for a definite automatic unit KEA 071-SPL. The declared current ratings of relay contacts shall not be exceeded! Each electric coil, connected to control outputs, shall be fitted with suppresser diodes (in case of DC coils) or shall have adequate anti-interference protection! TERMINALS 1-14: FAULT SIGNAL INDICATIONS 1-14 These terminals are provided as inputs for fault signal circuits 1 to 14; the external control contacts for these signals are to be connected to L[-] potential. TERMINAL 15: MAINS OFF To indicate mains circuit breaker s position, an auxiliary contact (NC, coupled to L[-] potential) of mains circuit breaker (or contactor) has to be connected to terminal 15, as a response signal. TERMINAL 16: GENERATOR OFF To indicate generator circuit breaker s position, an auxiliary contact (NC, coupled to L[-] potential) of generator circuit breaker (or contactor) has to be connected to terminal 15, as a response signal. The automatic unit KEA 071-SPL is fitted with an interlocking circuit, which prevents the generator circuit breaker from direct closing in case of connected mains supply. The automatic unit KEA 071-SPL is fitted with an interlocking circuit, which prevents the mains circuit breaker from direct closing in case of connected generator supply. TERMINAL 17: TERMINAL 18: When an L[-] potential is connected to terminal 18 and when operational mode AUTOMATIC is selected, the start of generator set will be initiated and the load will be transferred from mains to generator supply. The generator circuit breaker also would be closed automatically, when the generator set should be running under operational mode TRIAL, or in mode AUTOMATIC, started by signal REMOTE START (WITHOUT LOAD TRANSFER). When mains voltage is available, the change-over BLOCKING OF MODE SELECTION When an L[-] potential is connected to terminal 17, the selection of operational modes by push-buttons will be blocked. This could be performed, for example, by a key-operated switch, to avoid a change of selected mode by unauthorized persons or by error. REMOTE START DEMAND (WITH LOAD TRANSFER) takes place with an overlap synchronizing, that means, without an interruption. On disconnecting the signal to terminal 18, the generator circuit breaker will be tripped after reconnection delay, and the generator set will be shut-down after idle running time, provided, there is no signal for remote START WITHOUT LOAD TRANSFER available. TERMINAL 19: EMERGENCY SHUT-DOWN When an L[-] potential is connected to terminal 19, control unit, the operational mode selection has to the generator set will shut-down immediately. The be set to position OFF. This is possible only, when automatic control unit will be locked-out for any further starting attempt (indicated by signal AUTO- otherwise, the LED indication AUTOMATIC DEthere is no longer the L[-] potential at terminal 19; MATIC DEVICE LOCKED). To reset the automatic VICE LOCKED would remain lighted. TERMINAL 20: When an L[-] potential is connected to terminal 19, the load transfer between mains and generator OVERLAP SYNCHRONIZING ACTIVE supply (in operational mode TRIAL) and the reconnection to mains supply (in operational mode