Capricorn Controls Data & Application Note Page 1 of 6 SUM340 SUMMATION BOARD Genset Controls - Timers/Monitors/Trips - Battery Charging Spares & Accessories - Custom Products The SUM340 Summation Board can be used with 2, 3 or 4 set paralleling systems when interfaced between the KW on each Generating Set and the ADM600 Duty Control Module. The SUM340 monitors the load demand from each generating set and provides Call / Drop signals for the ADM600 so that it can signal to the individual engine controllers to start and stop sets in order to meet the demand. The 4-20mA input from the KW transducer of each Generating Set is converted to an analogue voltage proportional to the SUM of these inputs (total power delivered to the Load). Four Trip-Amplifiers convert this voltage into relay outputs for : CALL-2 nd, CALL-3 rd, CALL-4 th and SYSTEM OVERLOAD. This new version SUM340 differs from previous units in that an extra gain stage has been added after each of the four current to voltage (I >V) converters. This simplifies final calibration in that the (4) I > V converters and (3) Call / Drop Trip-Amplifier stages can be factory calibrated and never require adjustment, even if the SUM340 is used with different set sizes, KW s or numbers of sets. I > V Converters Trip Amplifiers Relay Outputs Overload Call 4 th Call 3 rd Call 2 nd Test Signal Power Supply The five sections of circuitry are -- 1/ Power Supply : a common 12V or 24VDC Supply (normally from ADM600) is converted into + 6V and - 6V for the electronic circuits. The Green LED indicates when the unit is powered. E. & O. E. The Proven Solution to Power Controls DA03SUM340-1
Capricorn Controls Data & Application Note Page 2 of 6 2/ Current to Voltage Converters : using precision Instrumentation Amplifiers, each 4 20mA input is converted into a 0-1.0V analogue voltage representing 0 100% full scale of the KW. Note: this calibration should never require adjustment. A separate post-amplifier stage has been added to each Instrumentation Amplifier so that the output can be adjusted to 1.0V for each Generator at Full Power. Each output has an isolator slide switch, connected to the summing amplifier. 3/ Summing Amplifier : this stage summates the V 8 I signals to produce a voltage proportional to the Total Power delivered to the load. This voltage is available on the 2- way terminal block to aid calibration & / or drive a Panel Meter. 4/ Trip Ampliers : four stages convert the Summing Amplifier output into Call-2 nd, Call-3 rd, Call-4 th and Overload signals required by the ADM600. The amber LEDs are lit when the relevant Call relays are energised. 5/ Test Signal : a switchable, dual-range constant-current output is provided on-board. CONNECTIONS Connector Term. Description Signal Connect to K1 1 Current Loop - GEN No.4 KW 2 Current Loop + 4-20mA GEN No.4 KW 3 Screen 4 Current Loop - GEN No.3 KW 5 Current Loop + 4-20mA GEN No.3 KW 6 Screen 7 Current Loop - GEN No.2 KW 8 Current Loop + 4-20mA GEN No.2 KW 9 Screen 10 Current Loop - GEN No.1 KW 11 Current Loop + 4-20mA GEN No.1 KW 12 Output + 4-20mA Test Signal Dual Range K2 1 Relay: Overload N / C 2 C / O ADM600 term. 31 3 N / O ADM600 term. 26 4 Relay: Call 4 th Set N / C 5 C / O ADM600 term. 31 6 N / O ADM600 term. 37 7 Relay: Call 3 rd Set N / C 8 C / O ADM600 term. 31 9 N / O ADM600 term. 38 10 Relay: Call 2 nd Set N / C 11 C / O ADM600 term. 31 12 N / O ADM600 term. 39 13 Input +Ve Terminal 14 to Latch Overload 14 DC Supply +Ve ADM600 term. 31 15 DC Supply -Ve Common -Ve
Capricorn Controls Data & Application Note Page 3 of 6 CURRENT > VOLTAGE CONVERTERS ZERO GEN-4 KW GEN-3 KW GEN-2 KW GEN-1 KW SPAN K1 1 2 3 4 5 6 7 8 9 10 11 12 GAIN Switch-4 Switch-3 Switch-2 Switch-1 Switch-5 Test Point Description Signal Representing TP10 Genset 4 : Gain stage O/P 0 1000mV Genset 0 100% Full Power KW TP9 Genset 3 : Gain stage O/P 0 1000mV Genset 0 100% Full Power KW TP8 Genset 2 : Gain stage O/P 0 1000mV Genset 0 100% Full Power KW TP7 Genset 1 : Gain stage O/P 0 1000mV Genset 0 100% Full Power KW TP6 Genset 4 : I >V Converter O/P 0 1000mV KWTD 4 20mA (0 - Full Scale) TP5 Genset 3 : I >V Converter O/P 0 1000mV KWTD 4 20mA (0 - Full Scale) TP4 Genset 2 : I >V Converter O/P 0 1000mV KWTD 4 20mA (0 - Full Scale) TP3 Genset 1 : I >V Converter O/P 0 1000mV KWTD 4 20mA (0 - Full Scale) Switches 1 4 allow unused channels to be disconnected from the Summation Amplifier. This is important since an input of zero (KW) = 4mA and therefore an open circuit input represents 4mA and will result in a negative mv level being applied to the Summation Amplifier! The SPAN and ZERO potentiometers for each of the four Channels are factory calibrated and should never require adjustment. They set the I > V Converter outputs (TP3 to TP6) to 0 1000mV for 4 20mA inputs. The GAIN stage for each channel compensates for the fact that the Generating Set KW at Full Power is less than the KW at Full Scale (20mA). The GAIN potentiometers should not require adjustment unless the SUM340 is used on a different installation. A dual-range, constant current test signal is available from terminal 12K1. Switch-5 selects the 4mA or 20mA, factory calibrated levels. However, these levels can be re-adjusted using the adjacent potentiometers.
Capricorn Controls Data & Application Note Page 4 of 6 TRIP-AMPLIFIER section METER GAIN + -- M 15 way 2-piece Connector Overload Call 4 th Call 3 rd Call 2 nd K2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 THRESHOLD HYSTERESIS -- 6.0V Trim + 6.0V Trim Test Point Description Signal Representing TP12 Summation Amplifier Outpu mv TP11 Band-Gap Reference 1.25 V TP2 Internal Supply Rail -- 6.0 V TP1 Internal Supply Rail + 6.0 V The Threshold and Hysteresis potentiometers set the Call and Drop levels for each Trip-Amp circuit. These are factory calibrated and should never require adjustment. The Gain potentiometer compensates for any loss in the Summation Amplifier. This is factory calibrated and should never require adjustment. Connect meter M as shown to display the total power supplied to the load. A digital Multi-Meter is ideal for test purposes. However, for a permanent display use a (suitably scaled) 0-1mA Panel Meter and calibrate it with the Meter potentiometer provided. The +6.0V and 6.0V Trim potentiometers are factory calibrated and should not require adjustment.
Capricorn Controls Data & Application Note Page 5 of 6 INSTALLATION GUIDELINES Guidance Information for Installation of Capricorn Controls products to assist in maintaining Electromagnetic Compatibility. Every effort has been taken in the design of the products to comply with the CE regulations and standards of Europe. To maintain the integrity of the product the following general installation instructions are recommended as a good practise. 1) Follow the specific installation instructions as supplied with the product. 2) Site the product as far as possible physically from known sources of interfering signals. 3) Use qualified technicians for the installation. 4) All connecting cables are aerials, which can collect interfering signals. Therefore it is good practise to make the interconnecting wires as short as possible, properly terminated and of the correct size and rating. 5) Route the product connecting cables, especially control and signal cables away from power cables and cables known to carry high frequency signals. This includes rectifier circuits and AC/DC commutating circuits. 6) Where cables have to be run close to interfering sources, use screened cable or twin twisted cable. The screened cables require proper termination of the screen at the ends. This should be co-axial termination where possible and terminated outside of the metal case where the product is housed. Ensure a metal-to-metal contact is made. Pigtail termination of the screen is not good E.M.C practise either at case shielding or at connectors. 7) If interference problems still exist, consider using a screened metal enclosure, around either the product or the source of interference. Metal to metal contact should be maintained at all connecting surfaces. Note: Paint is a good insulator and will ruin any measures taken to eliminate Electro magnetic interference. 8) Some of the Capricorn Control products are panel mounted. Where these have external controls, electrostatic discharge from operators has been taken into consideration, but requires that proper connection to the earth terminal be made. 9) If EMC problems exist which cannot be solved by the above advise please contact Capricorn Controls. The above information is provided as guidance only in good EMC practise and no obligation can be inferred on Capricorn Controls for failure of the product to perform when installed.
Capricorn Controls Data & Application Note Page 6 of 6 SPECIFICATION CONSTRUCTION : Open Board construction and varnished as standard. TEMPERATURE : Operating -10 0 C to +55 0 C Storage -25 0 C to +70 0 C DIMENSIONS : CONNECTORS : INDICATORS : SUPPLY RANGE : INPUTS: 140 x 216mm (including connectors) x 30 mm deep (including spacers) Fixing Centres = 119 x 178mm x M4 Industry standard 12way and 15way Two-Piece connectors and a 2-way Terminal Block. All connections rated at 5A / 240V AC1 High intensity Light Emitting Diodes (LED s) (1) Green = Power On (3) Amber = Call relays energised (1) Red = Overload Relay energised 9-15 VDC (12V system) -- specify with order 16-32 VDC (24V system) -- specify with order a 4-20mA input for the KW on each Generating Set. OUTPUTS: Separate, volt-free change-over contact sets for: Call-2 nd, Call-3 rd, Call-4 th and System Overload. All contacts are rated at 5A / 230V AC1. Meter M 0 1mA / 0 5V representing Total Power to the load CALIBRATION example KW s 4 20mA = 0 300KW (each) Generating Sets at full Load = 240KW (each) CALL / DROP Threshold Description Inputs Voltage at meter M Call 2 nd 70% Full Power of one Set 13mA 700mV Drop 2 30% Full Power of two sets 2 x 5.85mA 600mV Call 3 rd 70% Full Load of two sets 2 x 13mA 1400mV Drop 3rd 30% Full Load of three sets 3 x 5.85mA 900mV Call 4 th 70% Full Load of three sets 3 x 13mA 2100mV Drop 4 th 30% Full Load of four sets 4 x 5.85mA 1200mV Overload 110% Full Load of four sets 4 x 17.86mA 4400mV Drop Overload 100% Full Load of four sets 4 x 16.8mA 4000mV CAPRICORN CONTROLS LIMITED INDUSTRIAL ELECTRONIC ENGINEERS SPECIALIST CONTROLS FOR ENGINE APPLICATIONS Thorpe Close, Banbury, Oxon., OX16 4SW. England Tel: +44 (0) 1295 272360 Fax: +44 (0) 1295 264766 E-mail: sales@capricorn-controls.com Web: www.capricorn-controls.com Keystart, Remote Start, Start-on-Demand, Mains Failure, Mutual Standby & Multi-set Controllers. Annunciators and Lamp Modules. Voltage, Current, Frequency, Speed, and Temperature Monitors. Timers. Transport Refrigeration Spares. Batteries, Battery Chargers and Power Supplies. Spares and Accessories. Customised Products and Bespoke Designs.