Delomatic 400 GAS CHP controller TCP/IP Modbus communication

Transcription

1 Delomatic 400 GAS CHP controller Document : A

2 Table of contents 1. ABOUT THIS DOCUMENT... 3 GENERAL PURPOSE... 3 INTENDED USERS... 3 CONTENTS/OVERALL STRUCTURE WARNINGS AND LEGAL INFORMATION... 4 LEGAL INFORMATION AND RESPONSIBILITY... 4 ELECTROSTATIC DISCHARGE AWARENESS... 4 SAFETY ISSUES... 4 DEFINITIONS GENERAL... 5 HARDWARE... 5 SOFTWARE FUNCTION 3 (READ) FUNCTION 6 (WRITE) DEIF A/S Page 2 of 28

3 1. About this document General purpose This document is the manual for DEIF s Delomatic-400 (DM- 400) GAS Combined Heat and Power (CHP) plant controller. The general purpose is to give the designer the data addresses of the TCP/IP Modbus. Please make sure to read this handbook before working with the DM-400 GAS controller and the gen-set to be controlled. Failure to do this could result in damage to the equipment or human injury. Intended users This manual is mainly intended for the designer. Contents/overall structure The document is divided into chapters, and in order to make the structure simple and easy to use, each chapter will begin from the top of a new page. DEIF A/S Page 3 of 28

4 2. Warnings and legal information Legal information and responsibility DEIF takes no responsibility for installation or operation of the generator set. If there is any doubt about how to install or operate the generator set controlled by the unit, the company responsible for the installation or the operation of the set must be contacted. In order to obtain safe and trouble-free use of the DM 400 GAS it is important that transport, storage, mounting and commissioning is done according to standards. The units are not to be opened by unauthorised personnel. If opened anyway, the warranty will be lost. Electrostatic discharge awareness Sufficient care must be taken to protect the terminals against static discharges during the installation. Once the unit is installed and connected, these precas are no longer necessary. Safety issues Installing the unit implies work with dangerous currents and voltages. Therefore, the installation should only be carried out by authorised personnel who understand the risks involved in working with live electrical equipment. Extra care must be taken that components are not replaced with power on the system. Definitions Throughout this document a number of notes and warnings will be presented. To ensure that these are noticed, they will be highlighted in order to separate them from the general text. Notes Be aware of the hazardous live currents and voltages. Do not touch any AC measurement inputs as this could lead to injury or death. The notes provide general information which will be helpful for the reader to bear in mind. Warnings The warnings indicate a potentially dangerous situation which could result in death, personal injury or damaged equipment, if certain guidelines are not followed. DEIF A/S Page 4 of 28

5 3. General Hardware Besides the TCP/IP webserver connection, the Ethernet TCP/IP holds the Modbus communication: Hardware base: Ethernet port: Cable to be used: 10/100 BASE-T Ethernet RJ45 socket 8-pole (8P8C) EIA/TIA 568 B - cable Software Modbus TCP/IP: The Delomatic-4 is the slave in the Modbus communication IP address: Configurable Factory setting: Port: Function codes: 3 Read holding registers 6 Write single register The address list is representing the standard DEIF layout. For specific customer sols, separate dedicated lists are provided. DEIF A/S Page 5 of 28

6 4. Function 3 (read) application information 4000 Software-Version - Application Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul # Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul # Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul # Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul # Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul # Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul # Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul # Interface-Version - Modul # Hardware-Version Modul # Software-Version - Modul # Software-Revision Modul #9 16 electrical values 4100 generator voltage L1-L2 16 V 4101 generator voltage L2-L3 16 V 4102 generator voltage L3-L1 16 V 4103 generator voltage L1-N 16 V 4104 generator voltage L2-N 16 V 4105 generator voltage L3-N 16 V DEIF A/S Page 6 of 28

7 4106 generator frequency 16 Hz 1/ generator current L1 16 A 4108 generator current L2 16 A 4109 generator current L3 16 A 4110 generator active load 16 kw 4111 generator reactive load 16 kvar 4112 generator Cos Phi 16-1/ mains voltage L1-L2 16 V 4114 mains voltage L2-L3 16 V 4115 mains voltage L3-L1 16 V 4116 mains voltage L1-N 16 V 4117 mains voltage L2-N 16 V 4118 mains voltage L3-N 16 V 4119 mains frequency 16 Hz 1/ mains Cos Phi 16-1/ busbar voltage L1-L2 16 V 4122 busbar voltage L2-L3 16 V 4123 busbar voltage L3-L1 16 V 4124 busbar voltage L1-N 16 V 4125 busbar voltage L2-N 16 V 4126 busbar voltage L3-N 16 V 4127 busbar current L1 16 A 4128 busbar current L2 16 A 4129 busbar current L3 A counters 4200 active energy, generated [High] 16 kwh 4201 active energy, generated [Low] 16 kwh 4202 active energy, consumed [High] 16 kwh 4203 active energy, consumed [Low] 16 kwh 4204 reactive energy, generated [High] 16 kvarh 4205 reactive energy, generated [Low] 16 kvarh 4206 reactive energy, consumed [High] 16 kvarh 4207 reactive energy, consumed [Low] 16 kvarh 4208 operating time [High] 16 h 4209 operating time [Low] 16 h 4210 breaker operations GCB [High] breaker operations GCB [Low] breaker operations MCB [High] breaker operations MCB [Low] start attempts [High] start attempts [Low] service timer engine [High] 16 h 4217 service timer engine [Low] 16 h 4218 service timer oil [High] 16 h 4219 service timer oil [Low] 16 h 4220 service timer spark plugs [High] 16 h 4221 service timer spark plugs [Low] 16 h 4222 par. counter 1 [High] 16 Free DEIF A/S Page 7 of 28

8 4223 par. counter 1 [Low] 16 Free 4224 par. counter 2 [High] 16 Free 4225 par. counter 2 [Low] 16 Free 4226 par. counter 3 [High] 16 Free 4227 par. counter 3 [Low] 16 Free 4228 par. counter 4 [High] 16 Free 4229 par. counter 4 [Low] 16 Free feedback circuit breakers GCB closed GCB position failure MCB closed MCB position failure Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare 1 digital input functions smoke detector emergency stop watchdog safety chain low cool water level ext. loss of mains Pickup GCB opened GCB tripped fault engine cooling water flow fault engine cooling gas alarm fault enable operation start demand Acknowledge filter maintenance CH4 calibrating fault auxiliaries gas pressure A gas tight control A gas temperature A exhaust back pressure room air limiter 1 DEIF A/S Page 8 of 28

9 fault emerg. cooling system mixer pos. lean fault intercooler system winding temp. lim lube oil level max lube oil level min com. Pressure gas alarm warning fault gas alarm device com. temperature A island operation demand gas B fresh oil min storage waste oil max storage fresh oil min day gas tight control B gas temperature B fresh oil max level day tank bypass opened bypass closed MCB opened MCB tripped gas pressure B par. counter par. counter par. counter par. counter par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message par. message 21 1 DEIF A/S Page 9 of 28

10 par. message par. message par. message par. message par. message par. message par. message par. message par. message SDB Heating circuit dp-limiter fresh oil min level fault cool.sys start prepare ok STB STB Limitstop emergency cooler cold limitstop emergency cooler warm limitstop heating circuit cold limitstop heating circuit warm SDB fast stop fault Heating circuit water flow fault room vent mixer pos. rich generator fuse (AC voltage lost) automatic operation Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare 1 digital output functions rearm safety chain open safety chain GCB on command GCB trip (undervoltage coil) GCB off command open gas valve A1 1 DEIF A/S Page 10 of 28

11 open gas valve A ignition starter PKG amplifier Gas compressor on Engine cooling pump on Heating circuit pump on Engine cooler pump/fan stage Engine cooling fan stage Engine cooling fan stage emergency cooling pump/fan stage emer. Fan stage emer. Fan stage fresh oil pump/valve gas mixer clock gas mixer direction cooling water preheater open air flaps Room air reg. release collective fault collective warning ready for operation gas tight control A kwh puls close bypass MCB on command MCB trip command MCB off command gas tight control B open gas valve B open gas valve B island stage island stage island stage island stage Heating circuit bridge flow sensor Emergency cooling pump on room vent. stage room vent. stage Emergency cooling valve to cold Emergency cooling valve to warm Emergency cooler stage breaker back up Heating circuit valve to cold Heating circuit valve to warm release voltage reg release cos phi reg waste oil pump 1 DEIF A/S Page 11 of 28

12 engine running Spare Spare Spare Spare Spare Spare Spare Spare Spare 1 analogue input functions (Pt100/NiCr/Ni) 4500 exh.temp. A 16 C 1/ exh.temp. B 16 C 1/ exh.temp. after catalyst 16 C 1/ exh. temp. after heat exchanger 16 C 1/ exh.temp. bef. catalyst 16 C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ NiCrNi Res C 1/ cool.water temp. out 16 C 1/ lube oil temp. 16 C 1/ receiver temp. 16 C 1/ Heating circuit temp.bef.exchanger 16 C 1/ Engine cooler water temp. in 16 C 1/ room air temp. 16 C 1/ cool.water temp. in 16 C 1/ Heating circuit temp. after emer cooler 16 C 1/ Heating circuit water temp. return 16 C 1/ Heating circuit water temp. flow 16 C 1/ Heating circuit temp.after exchanger 16 C 1/ cold junction 16 C 1/ winding temp. U 16 C 1/10 DEIF A/S Page 12 of 28

13 4537 winding temp. V 16 C 1/ winding temp. W 16 C 1/ gen bearing A 16 C 1/ gen bearing B 16 C 1/10 analogue input functions (0/4 20mA) 4600 throttle pos. 16 % 1/ lube oil pressure 16 bar 1/ lambda voltage 16 ma 1/ receiver press. 16 mbar 4604 demanded power 16 kw 4605 cool.water press. 16 bar 1/ lube oil level 16 % 1/ mains power 16 kw 4608 CH4 value 16 % 1/ gas tank level 16 % 1/ battery voltage 16 V 1/ knocking signal gas pressure 16 mbar analogue output functions (0/4 20mA) 4700 speed governor 16 ma 1/ voltage regulator 16 ma 1/ setpoint Heating circuit valve 16 ma 1/ setpoint Generator cooler valve 16 ma 1/ kw instrument 16 ma 1/ setpoint Emergency cooler valve 16 ma 1/ setpoint air vent. 16 ma 1/ setpoint air flap 16 ma 1/ mixer (intern) 16 Stopcondition Level V DC power down DM4 software update watchdog reset DM4 watchdog reset DM4 20msec task not running frequently DM4 IO card data exchange timeout DM4 software fault under boot DM4 100msec task not running frequently DM4 1sec task not running frequently emergency stop button safety temperature limiter safety temperature limiter low water level cooling circuit low water level heating circuit differential pressure heating circuit DM4 watchdog relay does not work safety chain does not rearm safety chain does not trip safety chain relay fallen off smoke alarm DEIF A/S Page 13 of 28

14 gas alarm cooling water flow gas temperature line A gas temperature line B DI 'emergency stop button' is not assigned DI 'watchdog' is not assigned DI 'safetychain' is not assigned DI 'GCB closed' is not assigned DI 'GCB opened' is not assigned DO 'open safety chain' is not assigned DO 'rearm safety chain' is not assigned DO 'GCB on command' is not assigned DO 'GCB off command' is not assigned DO 'GCB trip command' is not assigned manifold IO assignment Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve 1 Stopcondition Level quick stop selected gas pressure line B gas pressure line A outputs overloaded or voltage out of range IOM outputs overloaded or voltage out of range IOM outputs overloaded or voltage out of range IOM outputs overloaded or voltage out of range IOM outputs overloaded or voltage out of range IOM max idle time elapsed acceleration state timeout start prepare timeout IO card uncalibrated open air flaps: G511 does not disappear opening exhaust flap: G182 missing DEIF A/S Page 14 of 28

15 opening exhaust flap: G181 does not disappear start failure stop failure testmode: starter operation too long speed input defective or engine still turning low lube oil level (analogue) low lube oil level (digital) low lube oil pressure high lube oil pressure lube oil overheated high cooling water temperature engine exit exhaust back pressure too high timeout gasalarm stage high cooling water temperature engine inlet fault cooling water flow low water level cooling circuit winding temperature limiter test mode SCANIA stop lamp generator tip fuse blown overspeed generator undervoltage generator overvoltage generator overfrequency generator underfrequency generator earth fault gas leakage check failed gas pressure controller before compressor gas temperature controller before compressor timeout open gas valves outputs overloaded or voltage out of range IOM Reserve gen bearing excess temperature A gen bearing excess temperature B ignition-counter: warm boot log Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve ignition-status: checksum error DEIF A/S Page 15 of 28

16 Reserve Reserve Reserve Reserve Reserve 1 Stopcondition Level manual mode phase sequence error U/f failure synchronization failure connect GCB timeout synchronization MCB failure fuse blown G213: failure cooling water pump deload timeout generator breaker position failure generator breaker has tripped generator breaker does not close generator breaker does not disconnect generator breaker disturbed: fuse blown generator overload generator overload generator overexcitation (reactive power export too high) generator underexcitation (reactive power import too high) generator overcurrent generator overcurrent thermal overcurrent generator overcurrent reverse power 1 fast reverse power 2 time-lag mains power failure mains underfrequency 2: stopping mains delta undervoltage 2: stopping mains star undervoltage 2: stopping mains overfrequency 2: stopping mains delta overvoltage 2: stopping mains star overvoltage 2: stopping too many asymmetry trips too many mains failures winding excess temperature U winding excess temperature V winding excess temperature W mixer control does not work Spare Spare Spare 1 DEIF A/S Page 16 of 28

17 Spare Spare Spare Spare Spare Spare Spare Spare 1 Stopcondition Level Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare 1 Stopcondition Level operation blocked on switchboard panel voltage control does not work cos phi control does not work speed control does not work power control does not work low water level intercooler cooling water valve not moving: G212 does not disappear too high cylinder temperature: LR too big generator continuously below min power sensor defect lube oil pressure lube oil pressure too low while generator breaker closed stop because of too hot exhaust wire break P150 exhaust back pressure P150> exhaust back pressure too high wire break intercooler water temperature intercooler water too hot short circuit of sensor intercooler water temperature sensor defect lube oil level (analogue) lube oil level max (analogue) DEIF A/S Page 17 of 28

18 lube oil level max (digital) load reduction because of gas level too low stop because of gas level too low wire break gas level wire break gas pressure operation stopped from remote operation stopped wire break T208 lube oil temp wire break T201 engine cooling water inlet temp wire break T202 engine cooling water outlet temp wire break T151 exhaust temp. after turbo charger mains power import signal defective stop: exhaust temp. before catalyst too hot stop: exhaust temp. after catalyst too hot stop: exhaust temp. after engine A too hot stop: exhaust temp. after engine B too hot stop: exhaust temp. after heat exchanger too hot stop: wire break cooling water pressure stop: cooling water pressure not in limit stop: cooling water pressure too low stop: cooling water pressure too high sensor defect CH calibration timeout stop: CH4-value too low load reduction because of CH4 value too low stop because of mains power mains breaker position failure mains breaker has tripped mains breaker does not close mains breaker does not disconnect mains breaker disturbed: fuse blown stop because of misfiring load reduction because of misfiring stop because of heat control Spare Spare Spare Spare Spare short circuit of sensor gen winding temp. U short circuit of sensor gen winding temp. V short circuit of sensor gen winding temp. W short circuit of sensor gen bearing A short circuit of sensor gen bearing B sensor defect gen winding temp. U DEIF A/S Page 18 of 28

19 sensor defect gen winding temp. V sensor defect gen winding temp. W sensor defect gen bearing A sensor defect gen bearing B Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve ignition-communication fault ignition: read status fault ignition: read counter fault Reserve Reserve Reserve ignition-status: disc error ignition-status: overspeed shutdown ignition-status: no charge ignition-status: open primary ignition-status: shorted primary ignition-status: open secondary Reserve Reserve Reserve Reserve 1 Stopcondition Level opening air flaps timeout: G512 missing room air temperature limiter cooling water valve: G211 & G212 at the same time low water level emergency cooler (L314) fault emergency cooler (G313) Heating circuit water after emergency cooler too cold wire break heating circuit after emergency cooler short circuit heating circuit after emergency cooler LR because oil temperature LR because water temperature engine exit Spare Spare 1 DEIF A/S Page 19 of 28

20 Spare Spare Spare Spare 1 Stopcondition Level closing air flaps timeout: G511 missing closing air flaps: G512 does not disappear fault limit-stops air flaps (closed and open) closing exh.-flap: limit-stop G181 missing closing exh.-flap: G182 does not disappear fault limit-stops exhaust flap (closed and open) fault waste oil pump fresh oil level min waste oil tank full pickup signal missing emerg. cooling valve: G311 & G312 at the same time emerg. cooling valve not moving: G312 does not disappear pump heating circuit disturbed analogue power demand input defective warning: exhaust temp. before catalyst too hot warning: exhaust temp. after catalyst too hot warning: exhaust temp. after engine A too hot warning: exhaust temp. after engine B too hot warning: exhaust temp. after heat exchanger too hot service lube oil run out service spark plugs run out service engine run out wire break T180 cold junction temperature wire break room temperature sensor heating water flow temperature too high parameter file transfer failed wirebreak T300 heating water temperature return wirebreak T302 heating water temperature flow wirebreak T152 exhaust temperature before catalyst wirebreak T153 exhaust temperature after catalyst timeout engine warming manual mode: bypass demanded manual mode: AWT demanded limitstop lean does not disappear limitstop lean does not appear DEIF A/S Page 20 of 28

21 limitstop lean reached in control mode limitstop rich reached in control mode steps missing > sensor fault lambda voltage wire break PT100 mixture temperature short circuit PT100 mixture temperature load reduction because mixture temperature over temperature mixture under temperature mixture Reserve timeout mixer moving to start position timeout mixer moving to idle position timeout mixer moving to parallel position timeout mixer moving to island position timeout mixer moving to rich position sensor fault receiver pressure BY: limit stop opened does not disappear BY: limit stop closed does not appear BY: limit stop closed does not disappear BY: limit stop opened does not appear BY: limit stops closed and open at the same time BY: too many operations per hour mixer limit stop lean and rich at the same time room air too hot cooling water pressure too low cooling water pressure too high wirebreak throttle position deviation of throttle position wirebreak T154 exhaust temperature after engine A wirebreak T155 exhaust temperature after engine B wirebreak T156 exhaust temperature after heat exchanger gas alarm stage gas detector device fault short circuit PT100 heating water temperature return short circuit PT100 heating water temperature flow over temperature heating water temperature flow short circuit PT100 heating water temp. after heat exchanger wire break PT100 heating water temp. after heat exchanger over temperature heating water temp. after heat exchanger SCANIA warning lamp DEIF A/S Page 21 of 28

22 SCANIA communication timeout misfirings detected change gas type Reserve Reserve ignition: spark reference A2 out of limit ignition: spark reference A2 out of limit ignition: spark reference B1 out of limit ignition: spark reference B2 out of limit ignition: spark reference C1 out of limit ignition: spark reference C2 out of limit ignition: spark reference D1 out of limit ignition: spark reference D2 out of limit ignition: spark reference E1 out of limit ignition: spark reference E2 out of limit ignition: spark reference F1 out of limit ignition: spark reference F2 out of limit Spare Spare Spare Spare no cranking speed detected Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare 1 Stopcondition (configurable messages) par. message DEIF A/S Page 22 of 28

23 par. message par. message par. message par. message par. message par. message par. message DEIF A/S Page 23 of 28

24 par. message par. message par. message par. message par. message par. message par. message DEIF A/S Page 24 of 28

25 par. message par. message par. message par. message par. message par. message par. message DEIF A/S Page 25 of 28

26 par. message par. message par. message par. message par. message par. message par. message DEIF A/S Page 26 of 28

27 par. message Spare Spare 1 Stopcondition mains protection mains protection: underfrequency mains protection: delta undervoltage mains protection: star undervoltage mains protection: overfrequency mains protection: overvoltage 1 delta mains protection: overvoltage 1 star mains protection: vector jump df/dt current asymmetry mains protection external device mains protection: undervoltage sequence Spare Spare Spare Spare Spare DEIF A/S Page 27 of 28

28 5. Function 6 (write) Resolutio Addres s Bit write (analogue values) n (bit) Unit Calculation demanded power 16 % = % mains power = kW kW CH4 value 16 % = % gas tank level 16 % = % start demand 1 0 = no start demand 1 = start demanded fast stop 1 0 = no fast stop 1 = fast stop acknowledge 1 edge 0 to 1 = acknowledge island operation 1 0 = no island operation demanded 1 = island operation demanded automatic operation 1 0 = manual mode / 1 = automatic operation CH4 calibrating 1 0 = CH4 measurement not in calibration 1 = CH4 measurement in calibration demand gas B 1 0 = gas type A selected 1 = gas type B selected Spare Spare Spare Spare Spare Spare Spare Spare Spare 1 DEIF A/S reserves the right to change any of the above. DEIF A/S Page 28 of 28