GENCON II PRO Features

Wexler Computer Systems Development Ltd. April 26, 2012

General
1.2 IOB2

GENCON R is a comprehensive computer system for the measurement, protection, management, paralleling and remote monitoring of generator-sets. The system is designed for OEMs, putting the emphasis on software exibility using the GENCON R system enables the OEM to manufacture a single control panel that ts practically all generator-set applications. The GENCON R system is made of three parts:

1.1

GENCON R

An auxiliary input/output board with digital and analog channels that mainly serves the engine (IOB1 is a simpler alternative with digital I/O channels only).

1.3

AVRx

Specications

are subject to change without notice

An interface module for the generator voltage regulator. 1

Measurements
Parameter 1 Volts Gen Phase A 2 Volts Gen Phase B Volts Gen Phase C 3 4 Volts Gen Phase A-B 5 Volts Gen Phase B-C 6 Volts Gen Phase C-A Amps Gen Phase A 7 8 Amps Gen Phase B 9 Amps Gen Phase C 10 Amps/Per-Unit Sequence Currents 11 Hz Gen Frequency 12 kW Gen Phase A 13 kW Gen Phase B 14 kW Gen Phase C 15 Total kW Gen 16 kVA Gen Phase A 17 kVA Gen Phase B 18 kVA Gen Phase C 19 Total kVA Gen 20 kVAr Gen Phase A 21 kVAr Gen Phase B 22 kVAr Gen Phase C 23 Total kVAr Gen 24 kW-Hour Count 25 P.F. Gen Phase A 26 P.F. Gen Phase B 27 P.F. Gen Phase C 28 % THD Gen Phase A 29 % THD Gen Phase B 30 % THD Gen Phase C THD = Total Harmonic Distortion Table 1: Generator measurements Transducer None None None None None None 5A CT 5A CT 5A CT None None None None None None None None None None None None None None None None None None None None None

GENCON R measures the electrical parameters of the gen-set 10 times per second. The measurements are true RMS and 0.5% accurate. GENCON R averages the incoming measurements and updates most LCD displays about once per second. GENCON R measures all the electrical parameters of three-phase1 generators in 4-wire and 3-wire congurations, see table 1. Also measured is one phase of the mains or the generator-bus that is the reference phase to synchronize the generator with, see table 2. The synchroscope measurements, see table 3, show the dierence between the generator parameters and the parameters of the reference phase. Table 4 shows the engine related measurements. Single lead resistive senders, the common automotive type, can also be used as GENCON R eectively cancels the battery ground noise. GENCON R has three 4-digit counters that record the systems activity, see table 5. A secret 10 year service counter is also in built for the optional MAINTENANCE REQUIRED alarm. Like the kW-Hour and the Hours-Run, the value of these counters is preserved while GENCON R s DC supply is switched o. The counters are protected by two passwords from user tampering.

Protection

The generator protective functions (table 6) and the engine protective functions (table 7) are based on the measurement system. All these functions have user adjustable trip-points and time-delays. Table 8 lists the gen-set protective functions that are contact based. GENCON R protections comply with the American NFPA level 1 recommendation.

Engine Management

GENCON R has eleven 380Vac/10A command relays. Table 9 shows a typical use of these relays in direct engine management. GENCON R can also be used
1 Single-phase

1 2 3

Parameter Volts Bus/Mains Phase A Hz Frequency Bus/Mains % THD Bus/Mains Phase A

Transducer None None None

Table 2: Mains/Bus measurements

support is available on order

1 2 3

Parameter Phase Shift Voltage Match Frequency Hz Slip

Transducer None None None

Table 3: Synchroscope Parameter Volts Battery RPM Speed Hours-Run Count Engine Temperature Oil Pressure Fuel Level Oil Temperature Transducer None Magnetic Pick-up None Resistive sender Resistive sender Resistive sender Resistive sender

1 2 3 4 5 6 7

Table 4: Engine measurements Counter name Engine Cranks Gen-Set Runs Gen-Set OnLoad Service Weeks/Days Table 5: Activity counters Alarm Over Voltage Under Voltage Over Frequency Under Frequency Inverse Time Overcurrent Negative Sequence Overcurrent Harmonic Distortion Illegal Phase Order Reverse Power Loss of Excitation Loss of Mains During Paralleling Voltage Not Built Frequency Not Built Dead Bus Protection Table 6: Generator protection

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Alarm Battery High Volts Battery Low Volts Engine Temperature Low Engine Temperature High Oil Pressure Low Oil Pressure High Fuel Level Low Fuel Level High Oil Temperature Low Oil Temperature High RPM Over Speed Engine Slow Crank Engine Over Crank Oil Pressure Not Built Engine Shutdown Failed RPM vs. Frequency Mismatch Table 7: Engine protection

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6 7 8 9 10 11

Alarm Remote Emergency Stop Low Oil Pressure Shutdown Low Oil Pressure Warning High Temp Engine Shutdown High Temp Engine Warning Low Temp Engine Warning Low Coolant Level Low Fuel Level Battery Charger Fault Air Damper Closed External Overload Table 8: Engine protection (contact inputs)

1 2 3 4 5 6 7 8

Function Preglow or Idle Speed Fuel Solenoid Starter Crank Air Damper Lubrication Pump Set Running Indication Visual Alarm Control Audible Alarm Control Table 9: Engine control relays

1 2 3 4 5 6 7

Function Phase/Frequency Synchronizer Voltage Matching Sync Check, dwell-time or freq-slip kW Load sharing, isochronous speed or droop kVAr Load Sharing, constant voltage or droop kW Export Control, adjustable ramp kVAr Export Control, adjustable ramp Table 10: Paralleling functions

with external Engine Control Units where it does not require, for instance, to have a magnetic pickup unit of its own.

Mains Failure Detector. It is based on the reference phase that GENCON R measures, see table 2. Time Delayed Transfer Logic (with an adjustable break to make delay). In-Phase Transfer Logic

Paralleling

GENCON R includes all the necessary functions for running a gen-set in parallel with the mains (peakshaving) or for running a gen-set in parallel with other GENCON R based gen-sets (load-sharing), see table 10. Using its TDM rmware GENCON R can maintain a constant generator bus frequency and voltage of up-to 8 or 142 gen-sets. Using its MODBUS-RTU rmware the number of parallel running gen-sets is unlimited but a supervisory system (Gview) is required to maintain the bus frequency and voltage levels. GENCON R controls the generator Hz and KWs directly through the engine governor or, when using its HYDRA rmware, using its A66 interface UP/DOWN contacts through the hydraulic governor servo motor. GENCON R controls the generator Volts and KVARs using its AVRx interface module through the generator voltage regulator.

Applications

The GENCON R system can be used in any gen-set application. In most cases it provides a complete solution. Where the requirements are non-standard, GENCON R oers a special operating mode, the generic mode, where it operates under the command of an external PLC. Single gen-set applications include: Prime Power. Mains Standby. Mains Standby with Soft Transfer. Peak Shaving (aka Peak Lopping).

Automatic Transfer Switch

Cogeneration (aka Combined Heat & Power). Multiple gen-set applications include: Random Access Load-Sharing with Power Ramp. 4

GENCON , as the tradition in Europe requires, has a built-in ATS logic. It includes:
2 A 14 gen-set system COMM II PRO units

is

formed

by

joining

two

 Load Dependent Start/Stop Sequencing (with optional balancing of the runtime and the breaker engagement counters). GENCON R can interface with most speed control (governor) and voltage regulator (AVR) models and in addition: It can cooperate with external engine management units. It can share the load with foreign gen-set controls through in built speed and voltage droop loops.

HMI/SCADA

Figure 2: Gpanes round-robin database). Gpanes can chart any logged data interval or export the data to a spreadsheet program for further analysis. A shutdown event can automatically generate an SOS e-mail message. Gview is an HMI software that is designed for the MODBUS-RTU variant of GENCON R rmware. It can control an arbitrary number of controllers through multiple serial RS485 ports.

Up to eight GENCON R controllers can be connected via a single Communicator3 unit to any HMI4 or SCADA5 system that uses the Modbus protocol, see gure 1. The maximal length of the RS485 cable is 1200m (=4000ft). The Communicator can also drive a 32 lamp alarm annuciator through the optional IOB3 module. Alarm Annunciator rs485 G1 G2 G8 COMM rs232 SCADA

Figure 1: The Communicator Gpanes is a powerful HMI/SCADA software that is designed for the standard rmware GENCON R controllers. Gpanes connects to the Communicator via a cable, a dial-up modem or a Modbus/TCP data link and provides the remote operator control Figure 3: Gview screens that update at real-time rate, see gure 2. Gpanes can be used safely across the Internet as it incorporates a standard, certicate based, Transport Layer Security (TLS). Misc Gpanes also includes a subsystem for data and 9 event logging (using a constant storage footprint Display 20 char x 4 lines LCD with backlight. User 3 COMM II PRO model translatable texts.
4 Human 5 Supervisory

Machine Interface Control and Data Acquisition

Faults logging Last 8 reports, time tagged. 5

Keys Stop, Alarm mute/reset, 4 menu navigation keys, 10 digit keys. Parameters Non-volatile eld-adjustable options, set-points and delays. Security Three password system. Indicators High intensity shutdown, warning and activity LEDs.

10

Technical data
listing E219920 (safety standard UL508).

Battery Voltage, 8 Vdc to 40 Vdc continuous (load-dump protected). Accuracy, 0.5% (true RMS). Front panel, completely sealed (IP65). Operating temperature, 20o C to +70o C (storage 30o C to +80o C). Four AC volts inputs (V1/V2/V3/V4), each electrically isolated to 7500 V (IEEE 587 class C). Three AC amps inputs (I1/I2/I3), each electrically isolated to 1500 V (1 minute). RS485 port, electrically isolated to 1600 Vac (1 minute) or 2000 Vac (1 second).