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4.6.4 Load takeover

G

Controller

Load

4.7 Flowcharts

4.7.1 Flowcharts

Using flowcharts, the principles of the most important functions will be illustrated in the next sections. The
functions included are:

●

Mode shift

●

MB open sequence

●

GB open sequence

●

Stop sequence

●

Start sequence

●

MB close sequence

●

GB close sequence

●

Load takeover

●

Island operation

●

Automatic Mains Failure

●

Test sequence

The flowcharts on the following pages are for guidance only. For illustrative purposes, the
flowcharts are simplified in some extent.

CGC 400 DRH 4189340786 UK

Functional descriptions

DEIF A/S

Page 20 of 96

Summary of Contents for CGC 400

Page 1: ...DK 7800 Skive Tel 45 9614 9614 Fax 45 9614 9615 info deif com www deif com 45 9614 9614 Fax 45 9614 9615 info deif com www deif com DESIGNER S REFERENCE HANDBOOK Compact Genset Controller CGC 400 Gen...

Page 2: ...ns 10 4 1 1 Standard functions 10 4 1 2 Operation modes 10 4 1 3 Engine control 10 4 1 4 Generator protection ANSI 10 4 1 5 Busbar protection ANSI 11 4 1 6 Display 11 4 1 7 M Logic 11 4 2 Terminal str...

Page 3: ...H5 manual 44 6 1 1 Engine communication 44 7 Additional functions 7 1 Start functions 45 7 1 1 Start functions 45 7 1 2 Digital feedbacks 45 7 1 3 Analogue tacho feedback 46 7 1 4 Oil pressure 47 7 2...

Page 4: ...puts 81 7 20 11 Binary 83 7 21 Input function selection 83 7 22 Language selection 84 7 22 1 Language selection 84 7 23 Text in status line 84 7 23 1 Standard texts 85 7 24 Counters 86 7 25 M Logic 87...

Page 5: ...llation or the operation of the set must be contacted The unit is not to be opened by unauthorised personnel If opened anyway the warranty will be lost Disclaimer DEIF A S reserves the right to change...

Page 6: ...the user the information he needs in order to suc cessfully set up the parameters needed in his specific application Please make sure to read this document before starting to work with the controller...

Page 7: ...he unit that is able to perform auto start and the CGC 413 is able to make the automatic mains failure AMF sequences The hardware for the two products is different therefore some of the sequen ces des...

Page 8: ...e Master Customer 2000 X Service 2001 X X Master 2002 X X X A parameter cannot be entered with a password that is ranking too low But the settings can be displayed without password entry Each paramete...

Page 9: ...to enter the parameters The customer password can be changed in jump menu 9116 The service password can be changed in jump menu 9117 The master password can be changed in jump menu 9118 The factory pa...

Page 10: ...GC 413 On the hardware point of view the CGC 412 has a lighter specification than the CGC 413 The table below describes which points differ from each other Feature terminal numbers Available on CGC 41...

Page 11: ...trip overview and rear side controller view 4 3 Measurement systems The CGC 400 is designed for measurement of voltages between 100 and 480V AC For further reference the AC wiring diagrams are shown i...

Page 12: ...1 L3 The following adjustments must be made to make the system ready for the split phase measuring example 240 120V AC Setting Adjustment Description Adjust to value 6004 G nom voltage Phase phase vol...

Page 13: ...be enabled individually in this measurement system 4 4 Applications 4 4 1 Applications and genset modes This section about applications is to be used for reference using the particular genset mode as...

Page 14: ...using the CGC 400 the plant type will be stuck to Single DG This means no CAN communication can be established with other units The active choice we can make here is the name of the application Using...

Page 15: ...uto mode description The unit automatically starts the genset and switches to generator supply at a mains failure after an adjusta ble delay time It is possible to adjust the unit to change to genset...

Page 16: ...nset and closes the generator breaker at a digital start command When the stop command is given the generator breaker is tripped and the genset will be stopped after a cooling down period The start an...

Page 17: ...ts when U f is ok Engine stops when time runs out Return When the test is completed the unit will return to the selected mode manual or auto Type Selection of one of the two types of tests simple or f...

Page 18: ...engine show BLOCK in the display and flash the MAN LED GB ON GB OFF MB ON MB OFF and START buttons are locked If block mode is selected using the display the block mode can only be deactivated from t...

Page 19: ...4 6 2 Automatic Mains Failure G Controller Load 4 6 3 Island operation G Controller Load CGC 400 DRH 4189340786 UK Functional descriptions DEIF A S Page 19 of 96...

Page 20: ...luded are Mode shift MB open sequence GB open sequence Stop sequence Start sequence MB close sequence GB close sequence Load takeover Island operation Automatic Mains Failure Test sequence The flowcha...

Page 21: ...uence End No No Yes Yes Mode shift enabled No Yes Mains OK timer timed out Initiate mains return sequence MB close sequence Continue in selected mode Yes No To enable mode shift a digital input has to...

Page 22: ...3 MB open sequence Start Load take over No MB closed No Yes Mains failure Open MB End Yes MB opened Alarm MB open failure Yes No CGC 400 DRH 4189340786 UK Functional descriptions DEIF A S Page 22 of...

Page 23: ...4 7 4 GB open sequence Start Is GB closed No Stop conditions OK No Yes Open GB End Yes GB opened Alarm Yes No CGC 400 DRH 4189340786 UK Functional descriptions DEIF A S Page 23 of 96...

Page 24: ...oil Deactivate run coil End No No Yes Stop conditions OK No Yes Genset stopped Alarm Yes No Yes AUTO mode Yes No Cooldown timer run out Stop relay Activate stop relay Yes No CGC 400 DRH 4189340786 UK...

Page 25: ...No Yes Start condition OK No Yes Max start attempts Ready to close GB Yes No Yes Start relay timer timeout Yes No Start relay ON Start failure alarm Alarm F U OK Run feedback detected Genset started...

Page 26: ...nce Start GB open No MB open No Yes Yes Mains OK End Yes Close MB GB open sequence GB open failure Mains failure MB close failure Yes No No No Yes CGC 400 DRH 4189340786 UK Functional descriptions DEI...

Page 27: ...s MB open sequence Volt freq OK Start seq OK MB open No Yes Mains OK End Yes Close GB MB open failure Mains failure GB close failure Yes No No No Yes No No No Yes Yes CGC 400 DRH 4189340786 UK Functio...

Page 28: ...ation Start Activate start input Start sequence MB open sequence GB close sequence End Deactivate start input GB open sequence MB close sequence Stop sequence CGC 400 DRH 4189340786 UK Functional desc...

Page 29: ...d operation Start End Operation Start input deactivated Start input active Start sequence GB close sequence GB open sequence Stop sequence CGC 400 DRH 4189340786 UK Functional descriptions DEIF A S Pa...

Page 30: ...tart eng open MB End Mains failure No Yes MB close sequence Open MB Start sequence GB close sequence Mains ok Time out Start sequence Open MB GB close sequence No Yes No Yes CGC 400 DRH 4189340786 UK...

Page 31: ...nning mode menu 7043 End Stop sequence Open MB sequence Yes Start Select test mode Simpel test Start sequence Test timer Full test Start sequence Test timer Close GB sequence CGC 400 DRH 4189340786 UK...

Page 32: ...e is the only sequence initiated e g press the START push but ton the engine will start but not close the breaker The following sequences will be illustrated below START sequence STOP sequence Breaker...

Page 33: ...vated before the start relay starter The time between the run coil and the start relay is setup in parameter 6151 In the following drawings this time is set to 1 sec Start sequence Normal start prepar...

Page 34: ...I 8 fuel level This means that if e g the oil pressure is not primed to the sufficient value then the crank relay will not en gage the starter motor The selection is made in setting 6185 For each of t...

Page 35: ...safety routine The running feedback selected is the primary feedback At all times all the types of running feedback is used for running detection If for some reason the primary choice is not detectin...

Page 36: ...ing detection based on the frequency measurement can replace the running feedback based on tacho or digital input or engine communi cation Running feedback Oil pressure setpoint menu 6175 Running feed...

Page 37: ...set in menu 6190 Start prepare 6180 Starter Normal prepare the start prepare timer can be used for start preparation purposes e g prelubrication or pre glowing The start prepare relay is activated wh...

Page 38: ...uence initiated tCOOL tstop Stop coil Stop sequence Cooling down time Stop coil Running feedback Sequence initiated The stop sequence will be activated if a stop command is given The stop sequence inc...

Page 39: ...delay after the running feedback has disappeared until a new start sequence is allowed The extended stop sequence is activated any time the stop button is pressed Cool down controlled by engine temper...

Page 40: ...ption of Breaker spring load time If no MB is represented the relays and inputs normally used for MB control become configura ble The GB can only be closed if the mains breaker is open The MB can only...

Page 41: ...7070 f mains failure 7060 U mains failure tGBC GB ON delay 6230 GB control tMBC MB ON delay 7080 MB control Example 1 7065 Mains fail control Start engine and open MB GB On MB On Mains failure detect...

Page 42: ...he frequency voltage measurements The conditions for the ON and OFF sequences are described in the table below Conditions for breaker operations Sequence Condition GB ON direct closing Running feedbac...

Page 43: ...operator s manual Information about display and menu structure can be found in the Operator s manual which is located on DEIF s homepage under documentation for CGC 400 CGC 400 DRH 4189340786 UK Disp...

Page 44: ...6 1 1 Engine communication Information about engine communication can be found in the Option H5 and H7 manual which is located on DEIF s homepage under documentation for CGC 400 CGC 400 DRH 418934078...

Page 45: ...ding to the shutdown fail class But if the starter motor has to disengage at 400 RPM and the oil pressure does not reach a level above the shutdown setpoint before 600 RPM then the genset would shut d...

Page 46: ...t is activated when the engine has reached its firing speed At the running speed the digital running feedback is activated The remove starter input must be configured from a number of available digita...

Page 47: ...input The drawing below shows how the setpoint of the remove starter is detected at the firing speed level The factory setting is 400 RPM 6170 Running detect t RPM RPMNOM Remove starter menu 6161 RPM...

Page 48: ...175 RPM Oil pressure Firing speed Remove starter input The drawing below shows how the setpoint of the remove starter input is detected at the firing speed level The factory setting is 400 RPM 6170 Ru...

Page 49: ...used combined with a compact breaker a direct controlled motor driven breaker With the setting compact the controller will need to use both a close command e g GB On and a open command relay e g GB O...

Page 50: ...t is waiting for permission to give the close command the LED indication for the breaker will be flashing yellow in this case If the breaker needs time to reload the spring after it has opened then th...

Page 51: ...way to make an alarm inactive when the events chosen in the menu be low are active The inhibit functionality is only available via the PC utility software For each alarm there is a drop down window wh...

Page 52: ...status Running not detected or the timer in menu 6160 not expired Generator voltage 30 Generator voltage is above 30 of nominal Generator voltage 30 Generator voltage is below 30 of nominal MB ON The...

Page 53: ...Run status 6160 Alarms can be adjusted to activate only when the running feedback is active and a specific time delay has expired The diagram below illustrates that after activation of the running fe...

Page 54: ...the display and digital inputs When activated the display will say Access lock when pushing the display buttons affected by the access lock please see the table below The input to be used for the acc...

Page 55: ...If the access lock is activated when the view menu sys tem is displayed it is not possible to access the setup menu If the access lock is activated when the setup menu system is displayed this button...

Page 56: ...quence based on the settings adjusted in the system setup Besides these settings it is possible to configure a digital input that can be used to control the mains return sequence This input is the Mai...

Page 57: ...timers can be used for e g start and stop The com mand timers are available in M Logic and can be used for other purposes than starting and stopping the gen set automatically The settings can either...

Page 58: ...ber in output A and output B and enable the function Change the relay function to limit in the I O menu Then the relay will activate but no alarm will appear If the relay function is not changed to li...

Page 59: ...s to be noted that the governor itself must handle the idle speed based on a digital signal from the unit see the principle diagram below When the function is enabled two digital inputs are used for c...

Page 60: ...nged in order to let the genset stay at the idle level before speeding up It also decreases the speed to the idle level for a specified delay time before stopping Start Stop RPM 300 1500 t tSTART tSTO...

Page 61: ...except for the oil pressure alarms RMI oil 6 7 and 8 which are active during idle run as well 7 10 5 Running signal The running feedback must be activated when the genset is running in idle mode 7 10...

Page 62: ...t stop ON No Yes Idle timer on Yes Lowspeed ON No starting Start the Genset Start the Genset Timer expired Genset running at f Nom Genset running at idle speed No Yes No Yes Yes No CGC 400 DRH 4189340...

Page 63: ...Genset running at idle speed Genset stop sequence No 7 11 Engine heater This function is used to control the temperature of the engine A sensor measuring the cooling water tempera ture is used to acti...

Page 64: ...e heater function is only active when the engine is stopped 7 11 1 Engine heater alarm If the temperature keeps dropping after the start setpoint has been exceeded an alarm will be raised if con figur...

Page 65: ...ax ventilation alarm Two alarms can be set up in menu 6470 and menu 6480 to activate if the temperature keeps rising after the start setpoint has been reached 7 13 Not in auto This function can be use...

Page 66: ...multi input if 4 20 mA is used Choose auto detection if an RMI is used 6556 Fail class The fail class of the fuel fill alarm Setpoints available in menu 6550 The fuel pump relay can be activated via M...

Page 67: ...he alarms and the subsequent alarm action Seven different fail classes can be used The tables below illustrate the action of each fail class when the engine is running or stopped 7 15 2 Engine running...

Page 68: ...X 5 Shutdown X X 6 Trip MB X 7 Trip MB GB X X X In addition to the actions defined by the fail classes it is possible to activate one or two relay outputs if additional relays are available in the uni...

Page 69: ...ing hours The number of running hours to activate the alarm The service timer alarm will be acti vated as soon as the running hours have been reached Day The number of days to activate the alarm if th...

Page 70: ...00 82 3 ohm 194 1 ohm Pt1000 823 ohm 1941 ohm RMI Oil type 1 1 0 ohm 195 0 ohm RMI Oil type 2 1 0 ohm 195 0 ohm RMI Temp type 1 4 0 ohm 488 0 ohm RMI Temp type 2 4 0 ohm 488 0 ohm RMI Temp type 3 0 6...

Page 71: ...t 16 Remove starter X X X Configurable Constant 17 GB position ON X X X X Configurable Constant 18 GB position OFF X X X X Configurable Constant 19 MB position ON X X X X Configurable Constant 20 MB p...

Page 72: ...the start sequence of the genset when manual mode is selected 5 Remote stop This input initiates the stop sequence of the genset when manual mode is selected 6 Test Changes the present running mode t...

Page 73: ...The unit requires this feedback when the breaker is closed or a position failure alarm occurs 20 Mains breaker open feedback MB position OFF The input function is used as an indication of the mains b...

Page 74: ...nset from start Parameter 6500 ena bles the alarm It is also possible to have the genset act on the input under running conditions with Stop swbd error parameter 6510 Parrallel ON needs to be on to ge...

Page 75: ...2 4 Prepare This function will close the relay as the first thing in the start sequence The relay will be closed for the time programmed in parameter 6181 This function is used for preheating the engi...

Page 76: ...n the PC utility software For each input two alarm levels are available the menu numbers of the alarm settings for each multi input is controlled by the configured input type as seen in the following...

Page 77: ...ure The unit of the measured value can be changed from Celsius to Fahrenheit in the PC utility software in order to get the desired reading in the display Offset parameter is used for compensation of...

Page 78: ...4 5 65 168 3 5 0 73 184 0 107 3 6 0 87 124 3 7 0 102 140 4 8 0 116 155 7 9 0 131 170 2 10 0 145 184 0 The configurable type is configurable with eight points in the range 0 2500 The resistance as well...

Page 79: ...48 22 4 36 8 7 4 130 266 28 9 140 284 22 8 150 302 18 2 The configurable type is configurable with eight points in the range 0 2500 The temperature as well as the resistance can be adjusted 7 20 7 RMI...

Page 80: ...points in the range 0 2500 The value as well as the resistance can be adjusted 7 20 8 Illustration of configurable inputs Setpoints Setpoint 1 Setpoint 2 Setpoint 3 Setpoint 4 Setpoint 5 Setpoint 6 S...

Page 81: ...e inputs is made with a resolution that fits the connected sensor It is recommended to follow the guide below when changing the scaling of the analogue inputs Scaling example 1 Use the utility softwar...

Page 82: ...put as required e g 0 5 bar The display will then show 0 at 4 mA 5 If needed it is possible to scale the input to fit the sensor Parameter 11010 CGC 400 DRH 4189340786 UK Additional functions DEIF A S...

Page 83: ...t up the 4 20 mA inputs HW as well as alarms the parameter file should be uploaded from the device to the PC and then saved In this way the settings will not be modified again if the parameters are re...

Page 84: ...English This is the default language and it cannot be changed In addition to the master language three dif ferent languages can be configured This is done via the PC utility software The languages ar...

Page 85: ...or GB ON BLOCKED Generator running GB open and an active Trip GB alarm SHUTDOWN OVER RIDE The configurable input is active ACCESS LOCK The configurable input is activated and the operator tries to act...

Page 86: ...us values are included and some of these can be adjusted if necessary for instance if the unit is installed on an existing genset or a new circuit breaker has been installed The table shows the adjust...

Page 87: ...e gen erator control system Please refer to the Help function in the PC utility software for a full description of this config uration tool 7 26 Buzzer 7 26 1 Buzzer The CGC 400 has a built in buzzer...

Page 88: ...ur sets of nominal settings Select the required input among the input events and select the nominal settings in the outputs Example Event A Event B Event C Output Dig input no 10 or Not used or Not us...

Page 89: ...160 0 kV 10 0 kV 160 0 kV All nominal values and the primary VT settings must be corrected after the scaling has been changed in menu 9030 7 30 Differential measurement 7 30 1 Differential measuremen...

Page 90: ...ameters for input selection for differential measurement 1 Inputs are selected from the input list as shown below avaible inputs are Multi inputs EIC measurements The relevant alarm setpoint is chosen...

Page 91: ...nly The CGC 400 includes as native a Modbus port This port can be configured as ASCII or RTU However parameters differ depending on if it is set to ASCII or RTU RTU mode ASCII mode Speed 9600 bps Spee...

Page 92: ...occur during the voltage decrease curve when unplug ging the unit the range of timer for this alarm will be changed It will not be possible to set a timer below 10 seconds for alarm CGC 400 DRH 41893...

Page 93: ...s to be taken into consideration An example A power generation system must not reconnect to a network when the voltage is 85 of Un 0 U 110 0 In order to ensure reconnection within this interval a cont...

Page 94: ...minal voltage 400 230 400 230 Voltage 10 error 380 207 360 185 The alarm will occur at two different voltage levels even though the alarm setpoint is 10 in both cases Example The below 400V AC system...

Page 95: ...he measured voltage on the generator voltage terminals The result can be expressed as a curve function where the voltage setpoints are fixed values and the current setpoints can be adjusted menu 1100...

Page 96: ...Reference Handbook relates to the parameters 1000 1990 2010 2790 3000 3610 4120 4970 5000 5070 6000 6990 7000 7680 9000 9150 For further information please see the separate parameter list document nu...

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