KUHSE
OPERATIONAL INSTRUCTION Genset Automatic Control Unit for start-stop of em. power gensets Type:
KEA 081 - NSTR
TA81NX0-E.01 September 1999 Replaces : July 1999
APPLICATION OF AUTOMATIC CONTROL UNIT The automatic control unit KEA 081-NSTR is applied in emergency power supply installations. Difference to the type KEA 071-NSTR is that this module does not need a relay unit (RZ) because 18 output relays (max. 1 amp., 35 V GS) are integrated. The unit may be applied to 12 volt - or 24 supply voltage, the voltage range is pre-selected by means of a unit internal selector switch. A measuring accessory MZ 081 is required in order to measure the mains- and generator voltage. This measuring accessory (without connecting cable to KEA unit) belongs to the scope of delivery. The mains- and generator voltage is measured in 3phase mode. It is monitored against: -
under- and over voltage, under- and over frequency, asymmetry.
For monitoring of the installation and of the genset following is provided: -
14 external fault signal indications,
-
4 internal fault signals each, initiated from mains- and generator voltage sensor,
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Function of the output relays and of the relevant parameters are adjustable by means of a Laptop. The KEA unit is provided with an optical fibre conductor (OFC) interface, by which an automation control system (ZLT) ( a protocol emulator might be required), a fault signal extension or a remote monitoring system (TELEMON) may be connected. Recording of the operation conditions and possibly arising fault signals can take place by means of an additional module
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mains failure detection, activation of start pre-conditions, starting-up of prime mover on start release, change-over from mains to generator supply, frequency control on island operation mode, genset monitoring and protection, detection of re-established mains voltage, change-over to mains supply, running-out and shutdown of the genset, battery voltage sensor.
The automatic unit contains following software:
WARNING HINTS ⇒ This unit must be applied only for the purpose mentioned under 'DESCRIPTION'. ⇒ Installation and commissioning must be carried out by sufficiently qualified staff only. ⇒ Applicable regulations, especially the VDE rules, are to be observed. ⇒ The unit's classifying must be carried out in a way to except absolutely hazards against persons and things.
TABLE OF CONTENTS Design
page 3
Operation- and indication elements page 3 Operation and functions Push button selector OFF/RESET Push button selector HAND Push button selector AUTOMATIC Push button selector TRIAL Push button START Push button LAMPS TEST Push button ALARM OFF
page page page page page page page page
3 4 4 4 5 5 5 6
Operational- and fault signals Controls ON Automatic unit locked Start indication Overcrank / engine trouble
page page page page page
6 6 6 6 6
Mimic diagram / voltage sensors
page 6
Fault signal indications Overspeed
page 7 page 8
Battery under voltage Fault signals 13 and 14 Mains c.b. tripped Generator c.b. tripped Engine does not stop Internal signals of the voltage sensors
page page page page page
8 8 8 8 9
page 9
Programs Starting-up program Operate- / shut-down solenoid / gas magnetic valve Run-up detection Frequency control on emergency power sully mode Emergency stop / emergency OFF
page 9 page 9
Technical data Purchase order numbers Dimensions, connection MZ 081 Connecting diagram KEA
page 10 page 10 page 11 page 12
page 9 page 9 page 10 page 10
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DESIGN The automatic control unit is provided for installation into the switchboard front door. Protection degree IP 44 is attained at installed status. The fault signal indications and the operation push buttons are marked by interchangeable text labels. The measuring accessory MZ 081 is fitted with a snap-on fastening for DIN EN 50 022 rail. It is provided for installation on the mounting plate and fulfils the protection degree IP 00. It is connected to the automatic unit by means of a multi-core cable and serves for mains- and generator voltage monitoring.
conductor (OFC) interface, by which a PC or Modem can be connected. By this the following settings are enabled (input is password-protected): -
-
-
The automatic unit is fitted with an optical fibre
codification of the fault signal indications for warning or shutdown, NC- or NO circuits, delayed or un-delayed, generator c.b. tripping /not tripping, classifying of the response values of voltage and frequency sensors, of delay and running periods of time and other function blocks, indication of the actual status of the external signal contacts, of actual values of voltages, frequencies, time stages and the engine speed.
OPERATION- AND INDICATION ELEMENTS LEDs for basic functions
LEDs for fault indications according to customers order LEDs for mains voltage and frequency LEDs for generator voltage and frequency Push button mains ON Push button gen. ON
LEDs for Fault signals according to customers order
Push button mains OFF Push button gen. OFF Signal: gen. c.b. is ON Signal: mains c.b. is ON
Push button selector
Push buttons
OPERATION AND FUNCTION All the indicating and operating elements are arranged clearly visible on the automatic unit front plate. The operation modes are to be selected by means of four push-buttons with integrated LEDs, showing the actual selected position. The push-button selector may be locked-out
electrically by an input (e.g. by connecting a keyoperated control switch); so an unintentional or unacceptable change of a decided selection can be avoided. By means of the push-button selector, the following modes of operation are to be selected.
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PUSH BUTTON SELECTOR: OFF On connecting the automatic control unit to battery voltage, this operational mode position will be preselected automatically (Reset Function), to prevent the genset from starting unintentionally.
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On switching-over from any other operational mode to position OFF, following will be initiated:
Shut-down of genset (if running), Switching-off of all indicated fault signals, except fault indications 13 and 14, as long as the corresponding alarm contact is active, Reset of automatic unit, in case the external EMERGENCY STOP contact is not active.
PUSH BUTTON SELECTOR: HAND On selecting this operational mode, a relay, which is configured for the function "Auxiliary Drives ON" is energized at once. The LED "START N I DICATION" shows flashing light. In case the start can be enabled, a reply signal is required (e.g. gas leakage tested, exhaust gas flap open, pre-lubrication pressure attained). The blinking LED START INDICATION changes (on engine stand-still) to steady light. In case no starting release is required, the input must be permanently connected to L[-] potential. Now the engine may be started-up by pressing the push-button START. By means of the mimic diagram arranged push button MAINS OFF (O) the mains c.b. may be disconnected, even on engine standstill. By means of the push button MAINS ON (I) it may be connected again. Provided, the generator voltage and frequency is within its rated value limits, then by means of the push-buttons MAINS OFF respectively GEN. ON, change-over to genset operation may take place.
Changing-back to mains supply takes place by means of the push button MAINS ON. On pressing the push button GEN. OFF, the generator c.b. is disconnected indeed, but the mains c.b. does not close accordingly. Connection of the mains c.b. has to be made manually. Similarly the mains c.b. is not automatically connected in case a fault signal (e.g. GENERATOR OVERCURRENT) appears during generator operation, which disconnects the generator. Pressing the ON push buttons is non-effective in case the voltage of the selected system (mains or generator) is not within its pre-set limit values or in case the phase sequence is incorrect. The remote start command does not effect an automatic generator circuit breaker closing. To stop the genset, the push-button selector is to be set to position OFF or (no remote start command alive) to position AUTOMATIC.
PUSH BUTTON SELECTOR: AUTOMATIC In case of faultless mains voltage the mains voltage supply is connected and the genset is on standby mode. The mains voltage is permanently measured and monitored. As soon as the programmed limit values of voltage or frequency are no longer kept, the condition will be indicated by means of the corresponding mimic diagram arranged LEDs (f<, f> U<, U>). After running-out of a programmable time lag the genset will be started-up then. The automatic unit may be classified in a manner either to initiate always a starting-up in case of mains failure, or starting-up takes place only in case of a simultaneous remote start command is given. This function enables an additional start interlock.
At the automatic start procedure first of all a relay is energized which performs the function 'auxiliary drives ON' (relay must be classified). The LED START INDICATION shows blinking light. In case the start can be released (e.g. gas leakage checked, exhaust gas flap opened, pre-lubrication pressure attained), a reply signal for the start release must take place. The blinking LED START INDICATION changes thereby (on engine standstill) to steady light. Provided no starting release is required, the input must be permanently connected to negative potential [L-]. If the genset should not start, even after complete cranking sequence program has elapsed, the fault
TA81NX0-E.01 signal OVERCRANK/ENGINE TROUBLE will occur and the automatic unit will be locked-out. When the generating set, after running-up, has reached nominal voltage and frequency, the mains circuit breaker will be disconnected and after a time lag (about 2 sec., programmable) the generator circuit breaker is closed. After mains voltage re-establishing a delay time starts running-down (reconnection delay period) before the generator c.b. is disconnected and after elapsed change-over delay the mains c.b. is connected again. To prevent the engine from a heat increase, the genset will run unloaded for an adjusted idle run time (cooling-down period), and then it will be shutdown. The automatic unit may be classified in a manner to initiate the start and change-over to generator operation also in case the mains circuit breaker is tripped by a disturbance (for switchboards according to VDE 107). The genset is started-up automatically in that case and takes over the emergency power supply. The mains c.b. tripping is indicated by a fault signal.
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deleted to enable mains reconnection operation. In case of faultless mains voltage the automatic unit changes back to mains supply after the reconnection delay period has elapsed. Additionally to the start initiation by mains failure the genset start can be initiated also by means of two remote start commands in this push button selector position: -
start along with change-over, start without change-over.
At a remote start along with change-over to generator operation, the genset is started-up similar to mains failure mode. Also change-back is similar to mains re-establishing.
The input start without change-over is provided for e.g. sprinkler installations. In case the genset is started-up via this input, only the starting program is running down, no change-over takes place. If now a mains failure should occur, however a changeover to emergency power supply takes place.
The fault signal MAINS C.B. TRIPPED must be PUSH BUTTON SELECTOR: TRIAL On selecting this operational mode, a relay, which is configured for the function "Auxiliary Drives ON" is energized. The LED "START INDICATION" shows flashing light. In case the start can be enabled (conditions similar to selector switch position HAND), the blinking LED START INDICATION changes to steady light. The starting program is initiated after start release. Provided, the generator voltage and frequency is within its rated value limits, then by means of the mimic diagram located push-buttons GEN. ON (I) or MAINS OFF (O) the generator can be con-
nected, or by means of the push buttons GEN. OFF (O) or MAINS ON (I) the generator can be disconnected. If during trial operation mode a mains failure occurs or a remote start with change-over command is given, change-over to generator operation take place. Now a manual generator circuit breaker disconnection is impossible. To stop the genset, the push-button selector is to be set to position OFF or (no remote start command alive) to position AUTOMATIC.
PUSH BUTTON: START In case 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 classified for gas engine, this program sequence will run.
PUSH BUTTON: LAMPS TEST
In case the diesel engine requires pre-glowing, arrangements for this must be realized externally. When another operational mode is selected or when generator set is running, the push-button is not active.
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The operative readiness of all the LEDs of the automatic control unit can be checked by means of this push-button, without initiating or suppressing an actual alarm signal.
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To include in this test other signal lights, assembled in switchboard panels, a relay can be classified to this function.
PUSH BUTTON: ALARM OFF By a pulse of this push-button, the audible signal caused by a fault signal, will be silenced.
After having eliminated the source of trouble, the visible LED signal may be switched-off by pressing the push-button once again.
OPERATIONAL - AND FAULT SIGNAL INDICATIONS Above the push button selector there are, arranged on the left side in two verticals, LEDs for indicating
important relevant operating and fault events. The following indications are provided as a basic fitting:
CONTROLS ON After starting-up of the genset, this GREEN LED signal indicates activating of monitoring circuits, which are depending on genset's run.
The indication is switched-off, as soon as the shutdown procedure is beginning.
AUTOMATIC UNIT LOCKED This indication shows, that an external EMERGENCY STOP push-button has been pressed or that a faulty condition has caused the genset to shut-down. The red LED indicates, that the automatic control unit as well as the genset is lockedout for any further starting attempt.
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.
START INDICATION This signal is lighting, if there is a starting demand, processed by the automatic control unit at AUTOMATIC mode or if the operational mode HAND or TRIAL is selected. As long as there is no enable signal for starting, the LED START INDICATION is flashing.
On enable signal, the LED changes to steady light. The indication is switched-off automatically, as soon as the genset's actual speed on running-up exceeds the firing speed. Now, it is not possible, to actuate the starter motor, not even manually.
OVERCRANK / ENGINE TROUBLE This signal is switched-on, in case -
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the genset has not started, even after the complete start sequence program has elapsed (simultaneously with signal AUTOMATIC UNIT LOCKED), the genset came to a standstill without any shut-down command emitted by the automatic
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control unit (with signal AUTOMATIC UNIT LOCKED), the genset is still running even after complete stop time has elapsed (without signal AUTOMATIC UNIT LOCKED).
M IMIC DIAGRAM / VOLTAGE SENSOR The mimic diagram symbolizes the mains incoming, the generator, mains- and generator circuit
breaker and the busbar. Push-buttons are assembled for:
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mains ON (I), mains OFF (O), generator ON (I), generator OFF (O).
The position of the mains- respectively generator circuit breaker is indicated by green LEDs, arranged below the corresponding push-buttons.
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Functions of the voltage sensors, switching points and delay times can be classified. Four red and two green LEDs each are provided for the mains- and generator voltage monitoring. These LEDs indicate, whether the voltages are within its nominal range or whether and which deviations are present. These LEDs, of first line below the mains- respectively generator symbol (from left to right), are indicating: -
under frequency (f).
The second LED line of LEDs indicates: -
under voltage / incorrect phase sequence(U).
The signal "Undervoltage" is also presented in case the measuring voltage of the generator is connected with a left turning rotating field or, in case the voltage shows a voltage vector asymmetry. The monitoring criteria of the mains-and generator voltage sensor may by classified in such a manner that: the sensor is non-effective, the corresponding LED operates as a static indication for the voltage sensor output, or the voltage sensor output is connected to an internal fault alarm. Static LED indication only: The corresponding red LED is alight, when an enabled monitoring detects a deviation from nominal value. During drop-out time lag, the mimic diagram arranged green LEDs remain lighted, until the delay time has elapsed. The function will be processed now internally. -
When voltage or frequency values have recovered to pre-determined limits, the red LED goes out at once and a delay release time starts running down. The green LEDs are flushing during this period and will change to steady light, when the delay time has elapsed. Internally, now the voltage system is recognized as "within nominal limits". The LEDs of the generator voltage sensor are out of order in case the operational mode OFF is selected, or in case no starting command is alive during operational mode AUTOMATIC. The LEDs of the mains voltage sensor are always active.
LED indication along with fault signal:
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When classified for fault alarm signals in case of deviation from nominal voltage or frequency values, the alarm will be activated only after drop-out time lag has elapsed. The green LEDs extinguish and the corresponding red LED is actuated as a normal
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fault indication, i.e. it is flashing, the horn sounds. This signal is, similar to all other fault indications, included into the common alarm signal.
FAULT SIGNALS The basic configuration of the automatic control unit include the possibility of processing 22 single fault signals, by which 4 each are provided for the mains- and generator voltage monitoring and 14 are freely applicable by the user. The fault signals are basically divided into three groups: -
-
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The operation depending fault signals (e.g. LOW OIL PRESSURE) are just released for monitoring with a time lag after running-up of the genset, noticeable by the LED signal CONTROLS ON. The operation independent fault signals (e.g. BATTERY UNDERVOLTAGE) are permanently active, except the selector switch is set to position OFF. The fault signals 13 and 14 are selector switch - and operation independent. They are applied for indications (e.g. LEAKAGE), which have to be permanently signalled, even on selector switch position OFF. The horn is not energized in position OFF, but the fault signals are included into the common alarms. These fault signals are acting similar to normal fault signals on having set the selector switch to any operational position (but not OFF).
The eight signals, which are internally used to monitor the mains- and generator voltage, are: -
mains under- and over voltage, mains under- and over frequency, generator under- and over voltage, generator under- and over frequency.
The fault signals may be configured as follows: -
-
operation depending delayed or un-delayed, signal effecting a warning only or signal along with simultaneous genset shut-down additionally, on warning signals: without or with generator c.b. disconnection. If, during automatic mode the generator is disconnected by means of a fault signal, the engine is stopped after elapsed running-out period and the automatic unit is locked-out. Coming-up of a fault signal is indicated by blinking LEDs. Simultaneously the audible signal is activated (for the pre-set duration). By means of a pulse given by the push button ALARM OFF (or automatically after running-out of the pre-set time) the audible signal is silenced, along with a change of the blinking indication into steady light. Several warning alarms which could occur in sequence, would repeatedly release the audible alarm; each alarm is indicated by the corresponding blinking LEDs as well. In case of warning alarms, another pulse by push button 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 signal AUTOMATIC UNIT BLOCKED. To reset the automatic control unit, after having eliminated the faulty condition (for example, unlocking of an external EMERGENCY STOP pushbutton), the push-button selector has to be set to position OFF/RESET. Now it is possible, to select again an operational mode.
signal contacts for NC or NO circuits, OVERSPEED
For overspeed monitoring either the internal generator frequency or the frequency of a separate speed sensor (pick-up or tacho generator) may be used.
BATTERY UNDER VOLTAGE
Provided a fault signal is classified for overspeed alarm, this fault signal causes always a genset shut-down, even in case all fault signals are configured for warning only (e.g. on sprinkler systems).
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An internal sensor may be classified for battery voltage monitoring. To monitor this signal properly, the voltage supply for automatic unit KEA 081 has to be connected to
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another source than the monitored battery (see National Standard DIN VDE 0108, Part 1, Section 6.4.4.5 or corresponding international rules).
FAULT SIGNALS 13 AND 14 These two signals may be delayed from contract closing 0 up to 25 sec., i.e. the alarm contact must be active for the programmed time delay to initiate a fault signal.
Furthermore these two fault signals are also active on selector switch position OFF, however without audible signal. Criteria, which have to be always signalled, can be monitored by this (e.g. tank filling level, leakage warning).
INTERNAL SIGNAL: MAINS C.B. TRIPPED The mains circuit breaker can be monitored against automatic tripping (e.g. by installed overcurrent tripping devices). In case this fault signal is provided (necessary to fulfil the VDE 107 rule), starting-up takes place on push button selector position AUTOMATIC respectively a change-over to emergency power supply during operational mode TRIAL.
The fault signal is internally triggered in case no position indication signal (mains C.B. is ON) takes place after running-out of the mains c.b. closing pulse. In case of utilization of a mains contactor, the pulse duration must be classified to a plausible value (e.g. 2 sec.).
INTERNAL SIGNAL: GENERATOR C.B. TRIPPED The generator circuit breaker can be monitored against automatic tripping (e.g. on installed overcurrent tripping device). Therefore a valid fault signal number must be classified (see classifying instruction) for this function. Additionally the function "warning/shut-down" must be classified for the assigned fault signal.
The fault signal is internally triggered in case no position indication signal (Generator C.B. is ON) takes place after running-out of the generator closing pulse. In case of utilization of a generator contactor, the pulse duration must be classified to a plausible value (e.g. 2 sec.)
INTERNAL SIGNAL: ENGINE DOES NOT STOP (ENGINE TROUBLE) If, after running-out of the stopping period, the "Running" signal of the engine is still active, the fault signal ENGINE FAULT is triggered. By this
an alarm is initiated in case the stopping device of the engine (e.g. defective stopping solenoid, faulty gas magnetic valve) is out of work.
INTERNAL SIGNALS OF VOLTAGE SENSORS The frequency - and voltage deviations of the mains and generator may be indicated as fault signals. Provided the function is classified as fault signal, the indication on variant voltage takes place as late as the dropping delay has running-out. The green LEDs are extinguish then and the corresponding red LED is illuminated as a normal fault signal, i.e. it is blinking. The horn sounds and the relevant common alarm is activated.
PROGRAMS
STARTING-UP PROGRAM
A fault signal does not effect the voltage sensor output. If, e.g. the fault signal GEN. UNDERFREQUENCY was active as warning signal, but the frequency is correct again, the fault signal remains active but for the internal control action of the automatic unit the generator voltage is considered as "correct".
TA81NX0.01 Due to the customers purchase order statements the starting program is classified either for diesel or for gas engine. The starting sequence on gas engines is as follows: -
starter motor ON, (2 sec. after exceeding ignition speed) ignition ON, (2 sec. after ignition ON) gas valve OPENED, starter motor continues ON for another 7 sec., as next gas valve CLOSED,
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In case of using diesel engines, fitted with preglowing device, an external pre-glow push-button must be provided, operative on operational mode HAND. For an automatic start sequence, the preglowing time (start delay) can be classified.
OPERATION- STOPPING SOLENOID / GAS MAGNETIC VALVE As standard mode the shut-down solenoid circuit is made in NO condition, i.e. the solenoid will be energized (for an adjusted time) to stop the genset. In case, the engine is fitted with an operate
solenoid which is de-energized to stop the genset, or in case the automatic control unit is applied to a gas engine, the relay K1 can be classified for the function OPERATE SOLENOID or GAS VALVE OPEN.
RUN-UP DETECTION The correct point of exceeding the engine's firing speed for disengagement of the starter motor has to be sensed doubtless. For this reason, the automatic control unit is serially provided with separate inputs for charging dynamo and tacho generator or pick-up.
the generator voltage of the genset can be processed for locking-out the starter motor. In case of gas engine control, always a pick-up or tacho generator with frequency signal output is required.
For safety reasons against unintentional engaging of the starter motor during engine run, additionally FREQUENCY CONTROL ON EMERGENCY POWER SUPPLY MODE During emergency power supply mode, the frequency can be regulated to a nominal value, independent of the genset load. Therefore, the engine must be equipped with a speed control device or with an electronic governor, fitted with control input.
The automatic unit emits adjusting pulses to the speed control device in case the frequency is not within classified limit values. There is a break between two pulses, which enables the engine to carry out the speed adjusting command.
EMERGENCY STOP / EMERGENCY OFF (EXTERNAL) Only one short pulse is needed to initiate the EMERGENCY STOP procedure. Independent of actual operational mode, the following functions will be activated: -
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output for the start pre-conditions switched-off, locking-out of the automatic control unit for any further starting attempt (indication: AUTOMATIC UNIT LOCKED).
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Weight approx. 2.2 kg Protection degree (installed): IP 44 Ambient temperature:
tripping of generator c.b., shut-down of genset,
T ECHNICAL DATA DESIGN -
KEA unit for flush mounting Dimensions (WxHxD): 260 x 170 x 90 mm
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Storage -20 °C ... +80 °C Operation 0 °C ... +55 °C Standards/Regulations: DIN EN 50 178
MEASURING ACCESSORY Dimensions (WxHxD): 225 x 70 x 40 mm Weight approx. 1 kg Protection degree: IP 00 POWER SUPPLY -
12 V or 24 V DC +/- 15 %, changeable Range of function ability: 9 V - 35 V DC
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Nominal voltage 3 x 100 volts, adjusting range 60 - 120 volts. Nominal voltage 230 / 400 volts, adjusting range 138 - 276 volts. Nominal voltage 3 x 400 volts, adjusting range 240 - 480 volts. Wrong rotating field causes indication
INPUTS, OUTPUTS, INTERFACE
MEASURING CIRCUITS, ANALOGUE INPUTS
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-
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Mains and generator voltage sensor, adjustable in 1-Volt-steps.
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14 terminals for fault signal contacts, optionally NO/NC circuits, 4 internal fault signals each of mains and generator voltage: 2 x voltage, 2 x frequency 18 outgoing relays, thereof 14 for classifying, max. contact rating 35 V DC, 1 amp.
Optical fibre conductor (OFC) interface for coupling to PC for adjusting jobs, to an automation control system by additional hard- and software, to a fault signal extension or to a remote monitoring system (TELEMON). Purchase order nos.:
2A81N X 0
mains- / gen.voltage 3 x 100 V
230/400 V
3 x 400 V
3 x 100 V 230 / 400 V 3 x 400 V 3 x 100 V 230 / 400 V 3 x 400 V 3 x 100 V 230 / 400 V 3 x 400 V
1 2 3 4 5 6 7 8 9
Example: Automatic control unit for emergency power plants, mains- and generator voltage 230 / 400 volts, ⇒ purchase order no.: 2A81N50
TA81NX0-E.01 09/99 DIMENSIONS
Cut-out of panel door, front view.
CONNECTING DIAGRAM MZ 081
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CONNECTING DIAGRAM AUTOMATIC UNIT MODULE
The unit may be applied to 12 volt - or 24 volt installations, the voltage range is pre-selected by means of a unit internal selector switch.
