MMC-4000 manual

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MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 2 von 94 24.01.2007

Update List

No. Date Changes, additions Replace previous documents, documents not

mentioned remain valid

Name Release

1 07.09.2006 Basisversion Mörderisch Robert

2 10.01.2007 Basisversion in Sprache Englisch überarbeitet Mörderisch Robert


Inhaltsverzeichnis

1. General 5 1.1. MMC System Description....................................................................................................5

1.2. "MTU motor management" system description...................................................................5

1.3. Safety instructions ................................................................................................................5

1.4. Safety chain ..........................................................................................................................5

1.5. CPU ......................................................................................................................................5

1.6. Selectivity of the Protective Equipment...............................................................................5

1.7. Shielded Cables ....................................................................................................................7

1.8. Circuit Diagram Documentation ..........................................................................................7

1.9. Maintenance .........................................................................................................................7

2. Start/Stop Procedure 8

3. Operating Conditions 12 3.1. “Manual” Operating Mode.................................................................................................12

3.2. “Automatic” Operating Mode ............................................................................................12

3.3. Grid Standby Operation .....................................................................................................12

3.3.1. Grid standby operation via external control instrumentation (not MCS)...................12

3.4. System (grid) connection: ..................................................................................................13

4. Floating Contacts 14

5. Operation & Display 15 5.1. Selector Switch / Button / Emergency stop (switching system) ........................................15

5.2. Display ...............................................................................................................................17

5.3. Parameter Entry..................................................................................................................17

5.4. Description of the Menu Bar ..............................................................................................18

5.5. Login ..................................................................................................................................21

5.5.1. Login with user and password....................................................................................21

5.5.2. Login via hardware USB dongle (optional) ...............................................................21

5.6. Main Menu .........................................................................................................................22

5.7. Plant Overview...................................................................................................................22

5.8. Engine Overview................................................................................................................23

5.9. Electrical Data ....................................................................................................................24

5.10. Water System .................................................................................................................29

5.11. Gas System.....................................................................................................................30

5.11.1. Alternative gas operation with two gas routes (optional) ..........................................30

5.11.2. Alternative gas operation with just one gas route (optional) .....................................30

5.12. Additional Function: Gas Compressor (optional) ..........................................................31

5.13. Gas Leak Test.................................................................................................................32

5.14. Oil System......................................................................................................................33

5.15. Fault Alarm ....................................................................................................................35

5.16. System Status Indications...............................................................................................35

5.17. Alarm log........................................................................................................................36

5.18. Power Controller ............................................................................................................38

5.19. Start / Stop Procedure.....................................................................................................42

5.20. Counter reading ..............................................................................................................43

5.21. Overview of Auxiliary Features .....................................................................................44

5.22. Cleaning Window...........................................................................................................44

5.23. Additional Function: Water Temperature Controller (optional) ....................................45

5.24. Additional Function: Mixture Water Controller (optional)............................................47

5.25. Additional Function: Mixture fan and pump (optional).................................................47


5.26. Additional Function: Emergency Cooling Water Controller (optional) ........................49

5.27. Additional Function: Emergency cooler fan and pump (optional) ................................49

5.28. Additional Function: Room Temperature Controller (optional) ....................................51

5.29. Additional Function: Room Air Fan Control (optional) ................................................51

5.30. Additional Function: CH4 Regulation (optional)...........................................................54

5.31. Gas Tank (optional)........................................................................................................56

5.32. Grid feed control (optional)............................................................................................58

5.33. Exhaust / Bypass Butterfly Valve Control (optional) ....................................................61

5.34. Heat operation motor (optional).....................................................................................62

5.35. Heat operation boiler (optional) .....................................................................................66

5.36. External temperature shift (optional) .............................................................................67

5.37. Heating Water Reservoir (optional) ...............................................................................68

5.38. Additional Function: Timer (optional) ...........................................................................69

5.39. Additional Functions: SMS/e-mail (optional)................................................................71

5.40. Service menu ..................................................................................................................72

5.41. External Communication (optional)...............................................................................73

5.41.1. Interface protocol: general notes ................................................................................75

5.42. M-Graph: Single channel intraday .................................................................................76

5.43. M-Graph: Single channel ...............................................................................................77

5.44. M-Graph: System ...........................................................................................................78

6. Operation & display: Service menu 79 6.1. System overview ................................................................................................................80

6.2. Fault alarm parameters .......................................................................................................81

6.3. Parameters ..........................................................................................................................82

6.4. Analog parameters..............................................................................................................83

6.5. Options parameters.............................................................................................................84

6.6. Emergency cooler parameters ............................................................................................85

6.7. Room fan parameter ...........................................................................................................86

6.8. Heat operation parameter ...................................................................................................87

6.9. Test Facility........................................................................................................................88

6.10. M-Graph: Single channel ...............................................................................................89

6.11. M-Graph: Single channel intraday .................................................................................89

6.12. M-Graph: System ...........................................................................................................89

6.13. M-Graph: System intrady...............................................................................................89

6.14. M-Graph: Heating Water ...............................................................................................90

7. Hardware descriptions 91 7.1. IPC......................................................................................................................................91

7.1.1. Possible fault causes...................................................................................................91

7.1.2. Establish remote access (e.g. customer).....................................................................91

7.2. Interface modules for control .............................................................................................91

7.3. CP3485...............................................................................................................................92

7.4. MSP....................................................................................................................................93

7.5. LAP 2440-3 Battery charging device.................................................................................94


1. General

1.1. MMC System Description

� Industrial PC with touchscreen and various interfaces, „Windows XP Embedded“operating system

� Programmable Logic Control, programming to IEC 1131-3

� Various interfaces (e.g. Ethernet, Profibus, RS232, Modbus RTU, … )

� MDE Synchronization & Protection

� The module control box contains functions for system components related to the motor. Various

controls (heating water, grid feed, gas tank…) and auxiliary drive actuators are integrated into the system.

1.2. "MTU motor management" system description

� MTU motor management contains all monitors and controls required for running the gas motor. � Communication with the MMC is per CAN bus. The current motor data (analog values, status

messages) and fault messages are transferred here. 1.3. Safety instructions

� The system may only be operated by authorized employees of the operating company.

Maintenance and switching work may only be by external staff if authorized employees of the operating company are present.

� The regulations of the accident prevention and insurance association must be observed when

working on the switching system. � Safety devices may only be replaced by authorized employees using the appropriate tools.

� The manufacturer’s maintenance regulations must be observed.

1.4. Safety chain

The safety chain is equipped with two safety combinations tested according to category 2:

� Machine safety chain (e.g. STB, combined emergency stop from PLC, ...) � Manual emergency stop safety chain (e.g. emergency stop at module cabinet, building

emergency stop, …)

If one of the safety chains is actuated, the corresponding drives are deactivated (e.g. gas valves, ...). All drives are deactivated if the emergency stop is actuated manually. 1.5. CPU

The CPU of the PLC is monitored by a watchdog. If it is actuated, all PLC outputs are shut down safely and the safety chain is actuated. The CPU can only be reset by restarting (switching the safety cut-out off and on). If the fault occurs again, contact the service department. 1.6. Selectivity of the Protective Equipment

The selectivity of the protective equipment (fuses, power switches, …) in the switching system is designed is designed for short-circuit current in grid standby or parallel operation. In grid standby operation, only the lower short-circuit currents of the connected generators are available. The selectivity


of the protective equipment is restricted in grid standby operation. The operator must ensure that the selectivity of the protective equipment is guaranteed in the consumer switching system in this operating condition.


1.7. Shielded Cables

� The shield must be attached very close to the contact point. � The shield must be attached on one side (module cabinet). � The unattached side of the shield must be insulated.

1.8. Circuit Diagram Documentation

The circuit diagrams are adapted specifically for each system. The diagrams are drawn up using the “WSCAD” drawing system. The following documentation is available after the circuit diagrams have been created:

1. Circuit diagrams (wiring diagram) 2. Cable lists 3. Parts lists 4. Terminal diagrams

1.9. Maintenance

The CP3485 (PLC) control unit is fitted with a battery. This battery must be replaced at regular intervals in accordance with maintenance regulations. When necessary, the filter mat of the filter fan must be cleaned. Maintenance intervals:

• Replace the battery in the CP3485 (PLC) central unit every 4 years or as necessary. • Clean/replace the filter mat when necessary


2. Start/Stop Procedure

Start procedure – Part 1

Start requirements 1Start command (local / remote) & manual/ or automatic mode

key switch enable, assembly is ready for operation,

no grid fault pending (for plant without grid standby, NLS is on

or "No NLS" option)

Automatic: All start conditions ok for automatic mode!

Yes

No start command to MTU motor managementNo

Start command to MTU motor management, Activate

auxiliary drives, activate cooling water pump, open exhaust flaps.

Start leak test (Request from MTU motor management)

Auxiliary drives on, cooling water pump on, exhaust flaps open,

leak test ok.

(Auxiliary drives on + leak test ok message to MTU

motor management)

Open gas valves (Request from MTU motor management)

Gas valves are opened. (Gas valves open message to MTU

motor management)

Phase 1

Start requirements 2

ja

Phase 2


Yes

No

No

To phase 3

Cancel start – Phase 1 by MTU motor management

Start cancel – Phase 2 via the MTU motor management



Phase 3


Wait until rated speed reached.

Generator voltage monitoring + generator frequency.

Activate overtravel time for auxiliary drives.

Yes

NoStart cancel – Phase 3

Rated speed reached (message from MTU motor management).

(Generator voltage > limit value) & (generator frequency > limit value).

Enable synchronisation (automatic or manual).

Enable speed adjustment. Automatic: Enable synchronisation +

Start time monitoring.

Manual: No synchronisation releasePhase 4

Generator switch is on + time monitoring not completeStart requirements 5

Yes

No

Parallel grid: Monitoring the power control, gradient

Grid standby: Activate grid standby mode (frequency controller)

Start cancel – Phase 4


Phase 3


Wait until rated speed reached.

Generator voltage monitoring + generator frequency.

Activate overtravel time for auxiliary drives.

Yes

NoStart cancel – Phase 3

Rated speed reached (message from MTU motor management).

(Generator voltage > limit value) & (generator frequency > limit value).

Enable synchronisation (automatic or manual).

Enable speed adjustment. Automatic: Enable synchronisation +

Start time monitoring.

Manual: No synchronisation releasePhase 4

Generator switch is on + time monitoring not completeStart requirements 5

Yes

No

Parallel grid: Monitoring the power control, gradient

Grid standby: Activate grid standby mode (frequency controller)

Start cancel – Phase 4


Stop procedure – Part 1

Phase 0

Stop condition 0

Genset in operation and stop pending.

Slow stop (gradient function)

or

Fast stop (open switch)

Slow

Fast

The genset is unloaded (gradient function).Phase 1

Jump to phase 2 immediately!

Stop condition 1 Power dropped below minimum.

Yes

No Stays in phase 1 !

Phase 2Open generator switch, activate speed control,

Start overtravel time for auxiliary drives.

Stop command to MTU motor management.

Module ready to start!

Stop procedure – Part 1

Phase 0

Stop condition 0

Genset in operation and stop pending.

Slow stop (gradient function)

or

Fast stop (open switch)

Slow

Fast

The genset is unloaded (gradient function).Phase 1

Jump to phase 2 immediately!

Stop condition 1 Power dropped below minimum.

Yes

No Stays in phase 1 !

Phase 2Open generator switch, activate speed control,

Start overtravel time for auxiliary drives.

Stop command to MTU motor management.

Module ready to start!


Emergency stop procedure

Phase 1 Genset in operation and emergency stop pending

Stop command to MTU motor management

All functions are

deactivated without

delay !

Phase 2

Manual emergency stopMachine emergency stop

(no manual emergency stop)

Stop command to MTU motor management

The following functions are always

performed:

-Close gas valves

-Open generator switch

-Switch to speed control

Various auxiliary drives may overtravel:

Cooling water pump

-Exhaust flaps

-Heating water pump

-Bypass flaps

-Lubricating oil supply

-Ventilation

Exception:

One of these functions triggered an

emergency stop, then it is also

deactivated.

Phase 3


3. Operating Conditions

3.1. “Manual” Operating Mode In this mode, the genset is started when the start command is sent (all start requirements must be fulfilled) and run until in the idle state. The genset remains in the idle state (max. 2 h) until the synchronization process is started or the stop button is pressed. After synchronization has been started and performed successfully, a setpoint of approx. 10% is set for the power controller. The power can now be controlled manually. 3.2. “Automatic” Operating Mode

In this mode, the genset starts automatically and synchronizes itself with the network when the start command is sent. The current setpoint is sent to MTU motor management and targeted, depending on the operating characteristics selected (set-value control, flexible value control, heat-controlled operation.

In automatic mode, various additional functions are incorporated in the start sequence. Depending on the active function (e.g. timer, power draw regulation, CH4 content etc.), the start release of the respective function is incorporated when the start command is activated. If this is not the case, a combined alarm is signaled.

If a drive or a controller (e.g. cooling water pump, heating water pump etc.) is set to manual mode and an automatic start is initiated, manual mode is reset (e.g. would overheat the genset if the cooling water pump was off).

3.3. Grid Standby Operation

In isolated mode, the power output is determined by the connected consumer loads. The speed control system must simply adjust back to the setpoint value following a load change. A frequency controller supplies this setpoint value. In the case of multi-engine plants, gensets operating in parallel must not burdened with different percentages of the load. An active-power load sharing system is provided to prevent this problem. It compares the generator active-power signals of the participating gensets and continues to supply adjustment signals using the remote governors to the speed control systems of the individual gensets until the loads are equalized (P range is 3 ... 5%).

A frequency controller simultaneously supplies equidirectional adjustment pulses to all speed governors to eliminate any frequency deviations as quickly as possible. An internal logic prevents contradictory signals from occurring as a result of power and frequency variations.

3.3.1. Grid standby operation via external control instrumentation (not MCS)

See separate document "Grid standby via external control instrumentation"


3.4. System (grid) connection: Synchronous generators may only be connected to an existing grid if voltage, frequency and phase angle are identical. A synchroniser is necessary in order to ensure that these conditions can be met. The synchroniser acts in conjunction with the speed controller to adjust the frequency and speed of the generator to enable system connection. Following system connection, the synchroniser is switched off.


4. Floating Contacts By default, the controller outputs various floating contacts. These contacts can be used to activate various drives or to query the system status. More of these kinds of signals can be sent for a specific project.

Ready: This contact remains closed when the following criteria are fulfilled:

� Key switch is set to module release

� Key switch is set to remote

� Key switch is set to automatic

� No stop or emergency stop signal is pending

External auxiliary drive on: The contact is activated during start-up. When the motor reaches the operating conditions, the overtravel timer is activated. When the genset is stopped again, the overtravel timer for the auxiliary drives runs down. This cools the motor. The contact is not deactivated until after the overtravel time.

The auxiliary drives are always switched off when an emergency stop is activated (safety chain actuated).

The auxiliary drives are also activated once for an overtravel if a PT100 temperature (HZW

temperature inlet/outlet, MCW temperature inlet/outlet) is exceeded on the heat module. This is intended to dissipate any built-up heat and to return the motor to the ready state.

GePS is on: The contact is activated as soon as the generator switch is closed. “Stop” combined signal: The contact opens when a stop or emergency stop signal is pending. The machine shuts down and the ready signal is switched off.

Motor is running: The contact is closed as soon as the motor reaches a speed of over 1000 rpm.


5. Operation & Display

5.1. Selector Switch / Button / Emergency stop (switching system)

Name Type of switch Position

Module release Key switch 0 / 1 Description

This switch prevents the module being operated. If the machine is idle, the module cannot be started. If the machine is running, a regulated stop is initiated.

0 = No release; 1 = Release


Local / remote control Key switch 0 / 1 Description

This switch sets the operation location. If the system is to be operated directly from the module, the switch must be set to “Local”. This allows all setpoints to be changed using the IPC. It also activates the “Start / Stop switch” on the control cabinet. If the system is to be operated remotely (remote start / stop, remote setpoints, control via interface), the switch must be set to “Remote”.

0 = Local operation; 1 = Remote operation


Manual / automatic Key switch 0 / 1 Description

In automatic mode, the system is started when the start signal is received, and the module is automatically synchronized with the grid and driven (gradually) to the power setpoint entered. All control tasks are performed automatically. The system is started after a start command in manual mode. The module starts and remains in the synchronization-ready state after the set speed is reached. In this phase, the speed can be adjusted manually (higher / lower pulses). Synchronization can be initiated by pressing another button (on the display). After successful synchronization to the grid, the machine stays at the minimum setpoint (approx. 10% power). The setpoint must be changed manually. All control tasks are performed automatically. “Local control” must be set for manual operation.

0 = Manual mode; 1 = Automatic mode


Start/Stop Key switch 0 / 1 Description

This switch is used to start the module locally. The “Local / remote control” key switch must be set to “Local”.



Grid standby operation release Key switch 0 / 1 Description

Automatic grid standby operation can be released using this switch. If this is the case, grid standby operation is initiated if there is a grid fault or a grid switch cabinet. In manual mode, the power switches (generator [GePS] and grid [GrPS]) can be operated manually (open, close). If grid standby mode is not released, the power switch (GePS) is opened immediately if there is a power failure.

0 = No release; 1 = Release


Grid failure test Key switch 0 / 1 Description

This switch is used to test the effects of a grid failure. A phase to MSP (MDE Synchronization & Protection) is interrupted when the button is pressed. The reaction actuated depends on the position of the “Grid standby operation” key switch. If it is released, the grid standby is initiated; if not the GePS is opened.

0 = No test; 1 = Start test


Reset Button Description

This button is used to acknowledge pending fault alarms. The safety relays are opened when an emergency stop is pending. The safety relays and the corresponding fault alarms can only be activated or acknowledged using this button. Only fault alarms for which no relay must be activated can be acknowledged via the display (R-button).


Emergency stop switch Emergency stop Description

The manual emergency stop chain is actuated immediately when the emer-gency stop switch is activated. All drives and the module are deactivated immediately. The emergency stop chain cannot be activated again until the switch has been unlocked (the switch can be unlocked using a key) and the reset button has been pressed.


5.2. Display All values imported from the module and the plant can be shown on the integrated touchscreen. The display is made up of various menus. The display is designed for touch operation. All operations can be performed without a keyboard or mouse. All entries can also be made using software keyboards. Various menus, parameters and switches are only released for certain users (no release => greyed out).

You must press the button and log in to activate them. The menus or parameters are released if the user is authorized.

If no user is logged in, all operations and parameters are blocked!

5.3. Parameter Entry All plant parameters required can be changed using the display. Parameters can be identified by the red text color. When these parameters are clicked, an entry window opens. Enter the parameter (by pressing the number buttons) and press “Enter” to confirm.

All parameters are monitored for the entry ranged. If the entry is outside the entry range, the value is changed automatically to the upper / lower threshold.


5.4. Description of the Menu Bar

Home Button Press this button to return to the start screen. You can keep pressing this button until the “Main menu” is opened.

Help Button Press the Help Button to view the version number of the current display and the control program on the PLC.

Only available from the main menu!

Language Selection Button This button is used to change the language. Two languages are always stored (German, English). The national language can also be integrated as a third language.



Fault Alarm Button This button indicates when a fault alarm is pending. These buttons are each linked with a combined fault alarm. Press one of the buttons to switch to the fault alarm window. There are three types of fault alarms:

� Emergency stop (E): The system is switched off immediately, e.g. when the emergency stop button is pressed.

� Stop (S): (Red alarm)

The system is stopped. This can be either a “controlled stop” or an “immediate stop”. Controlled stop: The module is relieved of the power load gradually. Immediate stop: The power switch is opened without delay.

� Alarm (A): (Yellow alarm)

A fault has occurred which dies not cause the module to be deactivated. The following states apply for all three buttons:

� No fault: The button is “blue”.

� A new fault is pending and has not been acknowledged:

The button is “red” and flashing.

� A fault is pending and has already been acknowledged: When a combined fault is pending and the operator has already acknowledged it (by pressing the “reset button”), the button turns “yellow” and no longer flashes.

Start Request � If this button is red => there is no start request at the moment. � If this button is green => there is a start request (e.g. remote control & remote start command

pending). Press this button to list all start conditions for automatic mode. All functions activated in the system are enabled and indicated. If the start condition is fulfilled (e.g. the gas tank enables the system), the gas tank LED lights green (if not, then it is red). This makes it easy to see which start conditions are missing.


Date/Time Button This button is used to set the time and date of the controller and the IPC. The project name is only displayed.

You can set the time and date of the controller and the IPC on this page. The time is important for marking the time of fault alarms. The data is entered in the red fields and then transferred to the controller by pressing the “Set time” button. If the transmission was successful, the current time (the values set) are shown on the left side and the second counter runs. The “Acknowledge alarm” button flashes when a fault is pending. This button must be pressed to acknowledge the fault and to allow you to repeat the procedure.

Attention: The year cannot be set earlier than 2000.

Nur vom Hauptmenü aus möglich!

Login-Button This button is used to release various parameters and menu items for users. Certain parameters are released for each user. This prevents unauthorized persons changing critical parameters.



5.5. Login

This button is used to log in as a defined user. Different parameters and menus are enabled according to the user logged in. For example, it may be possible to change the parameters of the room fan. You can only login in the main menu. The following two types of login are available.

5.5.1. Login with user and password For login this way you have to enter user and password in the Login form. Standard user and password: You will get this information separate from the operator manual. Procedure:

� Press the “Login” button � The login form opens.

� Enter the “User” and the “Password” (touch the corresponding entry field). � Press “Login” in the login form. � The current User, Level and Logout time are shown in the Status bar. � The window closes automatically after a short time.

Users are logged off automatically after a certain time.

If the entry is incorrect, “Wrong User or Password” appears in the Status bar.

5.5.2. Login via hardware USB dongle (optional) For this login type, no user or password must be entered. A USB dongle is inserted in the front USB port of the IPC, and then only the login button in the login window needs to be clicked. The computer checks the dongle and then enables the access level saved on the dongle. There is no automatic logout while the dongle remains inserted. When the dongle is removed, the user level is reset to 0 within 10 minutes.


5.6. Main Menu

The main menu appears automatically when the PC starts. This screen is the highest display level. Use the menu buttons to open the various sub-screens.

5.7. Plant Overview The plant overview varies from project to project. Plant-specific data are displayed on this page.


5.8. Engine Overview

Auf dieser Seite wird je nach Motortyp eine Übersicht aller Aufnehmer und Messwerte dargestellt.


5.9. Electrical Data This screen contains all important data on the generator and the grid. The overview and data depend on the options selected (e.g. with grid standby).

The GePS can be operated manually from this screen (the GrPS can also be controlled as an option for grid standby plants). The following requirements must be fulfilled:

� “Local/remote” key switch set to Local

� “Manual/automatic” key switch set to Manual

� Authorized user logged in

� The GrPS can only be activated manually in a grid standby plant.

GePS: The “Close” button does not cause asynchronous activation of the grid switch if the GrPS is closed. In the idle state, the switch cannot be closed.

GrPS:

The “Close” button does not cause asynchronous activation of the grid switch if the GePS is closed.


Load Level Control (optional)

It is possible to activate load release control in grid standby operation. Control is possible up to eight levels. When grid standby is initiated, control system issues the “Load release” command. Grid standby is then only resumed after a message has been received to say that load release was carried out successfully (LED Load rejection). When a message is received that the GLS has been closed the levels are reconnected again in staggered fashion. Connection is completed when the final level has been activated or overload occurs (evaluation optional). By staggering the connection, optimum load adjustment can be achieved for the engine. The number of load levels is set when setting the general parameters.

When machine is idle or grid switch is closed, all load levels are reconnected.

Message: “Load release successful” all messages for individual levels are connected in sequence

Levels that have been entered with “0” delay time, are not switched off (not even in the case of overload).

Load level contactors must be controlled so that contactors connect when couple relay is open. This

ensures consumer power is maintained by control unit in the case of a power failure or during repair work.

Overload monitoring: When the overload switch is activated (shaded green), power values are assigned to the individual levels. When actual power value > (power value (current level) + overload limit), a delay period starts up. Once this period has expired, a fault alarm is triggered (overload in grid standby operation) and one level is switched off. This procedure is repeated until value is reduced again to below limit or the final level is switched off. Levels are only reconnected when fault alarm has been acknowledged and value is below permitted limit. When a load is so large that the module cuts out because of too low a frequency, the monitoring system also ceases to work. Monitoring system also only checks next level has been connected if load has not exceeded module capacity (e.g. 90%). In this case, a fault alarm is also sent out and the next level is not connected.


Parameters for load level control: Delay (1-8) sec Level is only connected after delay time

has expired. Thereafter next delay time starts and another level is connected. Please note: It is not possible to set several different delay times (0, x, 0, …). e.g.: Level 1 = 0, Level 2 = 7, Level 3 = 0 In this case, all delay times will be adjusted to default value. This will be done automatically by the system.

Optional parameters for overload monitoring: Power value % A maximum permissible value for power

is assigned to each level. Expected power should not exceed this value. If values entered exceed the 100%, a default setting is made (30/30/30). This is done automatically by the system.

Overload limit value % This value is added to the total power value (sum of all active levels). If actual power value does not exceed the value calculated, a fault alarm is triggered after overload delay period has expired and the level is disconnected.

Overcharge delay sec When calculated limit value is exceeded, the time delay period starts. Once this time has expired, a fault alarm is triggered - “overload in grid standby” - and levels are disconnected as described above.


Cosphi regulator (optional):

The Cosphi can be adjusted variably by the MMC. To do so, the Cosphi controller on the generator is influenced by a motor potentiometer. The setpoint and the corresponding control parameters can be set via the display. Parameters for Cosphi control: Release % The Cosphi controller is not enabled

until the electrical output is greater than this limit value. Until this point, the plant is run at the permanently set Cosphi (set via the potentiometer on the generator controller)

Setpoint The setpoint required is specified here. The individual limits depend on the generator.

Ki I proportion of the controller. The greater the value, the faster the controller becomes.

Tn sec Adjustment time of the controller. The lower the value, the faster the controller becomes.

Pause time ms The next adjustment pulse is output after the pause time.

Pulse/pause time ms The adjustment pulse is output for the adjustable time.

Starting position KOhm The preset Kohm setpoint determines the Cosphi for the inactive Cosphi controller (output < release limit value). When the controller is enabled, the motor potentiometer starts at this value. The controller moves the motor potentiometer to this setpoint every time it is shut down.

Runtime ms The total runtime of the motor potentiometer is set here.


Generator data Press the Generator button to call up additional analog values from the generator.


5.10. Water System

This screen contains all sensors and drives for the hydraulic system. It is divided into two sections: “Heating water and cooling water”. The various functions can be activated or deactivated. The pumps can be operated manually.

You can also open the optional water temperature controller from this screen. To do so, press the regulation valve. Auxiliary drives: The auxiliary drives start without delay on startup and run on for a set time after shutting down. Parameters for the overtravel time of the auxiliary drives: Overtravel time: min.

Preheating: Module preheating allows the cooling water temperature to be kept within a set range. � Internal preheating via attached heating cartridges

The cooling water pump is also activated when preheating is activated. Warm up gradient (cutoff value) – optional Using this function, the power gradient is increased to an adjustable value after the GePS is activated. The gradient is only continued if the cooling water temperature has also exceeded a set limit value.

Only active in automatic mode! Parameter für Warmlauframpe: Setpoint power % When the cutoff point for the setpoint gradient is

activated, the power setpoint stops at this setpoint until the cooling water temperature IW has reached the setpoint SW. The power setpoint is not increased further until after this.

Cooling water motor °C The gradient is not continued until the set temperature is reached.


5.11. Gas System

This screen gives an overview of the gas route. The following gas system versions are available: � Single gas operation � Alternative gas operation with two gas routes � Alternative gas operation with one gas route

All necessary parameters and data are displayed or can be set. The optional gas condenser can be accessed from this page and the gas leak test can also be activated at the appropriate level.

5.11.1. Alternative gas operation with two gas routes (optional) Not enabled!!!

5.11.2. Alternative gas operation with just one gas route (optional) Not enabled!!!


5.12. Additional Function: Gas Compressor (optional)

The gas compressor is activated when a start request is received. After the switch-on delay time (time required to build up gas pressure), the rest of the engine start process is released. The gas compressor continues running after the engine is stopped. This time can be set. Gas compressor parameters: Switch-on delay sec The time that must expire before the motor can be

restarted. Switch-off delay sec The gas compressor continues to run for this time.


5.13. Gas Leak Test

The gas leak test can be performed manually if the machine is idle. To do so, click the “Manual” button. The button then turns orange. You can now initiate the test using the “Enable” button. All status indications can be observed.


5.14. Oil System

This screen gives an overview of the lubricating oil supply. It is divided into three sections: � Lubricating oil refilling for the genset (standard) � Control for old oil pump � Controls for an (optional) fresh oil pump

Oil refilling: Automatic oil refilling is activated by a request from the MTU motor management. In order to bridge the reaction time between when the refilling solenoid valve opens and the oil level monitor responds, the solenoid valve is actuated as follows. The solenoid valve is opened for the opening time TO when the request is received from MTU motor management. It is subsequently closed for the pause time TP. TO then begins again. This interplay is repeated until the MTU motor management request is no longer pending. See the oil refill counter for the number of requests from the MTU motor management. Oil refilling parameters: To sec Solenoid valve opening time Tp sec Solenoid valve pause time

Old oil pump: The old oil pump can be operated via the control. There are two ways of controlling the pump: � On-site operation via display

Activate manual button � Remote operation via key switch at heating cabinet

Functional description: The old oil pump can be selected in the display. The following buttons are available: � Manual � Start/Stop


Manual operation (press Manual button) When Start is pressed, it pumps until the optional Old oil tank overfill or Old oil tank fill level > max contact is activated or the pump is switched off manually. Fresh oil pump (optional): The fresh oil pump can be operated via the control. There are three ways of controlling the pump: � Automatic mode for oil refilling � On-site operation via display

Activate manual button � Remote operation via key switch at heating cabinet

Functional description: Automatic mode for oil refilling: The fresh oil pump is activated in the same intervals as the solenoid valve. The fresh oil pump can be selected in the display. The following buttons are available: � Manual � Start/Stop

Manual operation (press Manual button) When start is pressed, it pumps until the Level < min. contact is no longer pending on the refilling pump. The filling pulse is then activated until the Level > max. contact from the motor oil tank or the optional Fresh oil tank fill level < min. 2 contact is triggered. The pump can also be stopped manually.


5.15. Fault Alarm This screen provides an overview of all pending fault alarms. You can also open the optional alarm log. The log records all fault and operating alarms with times over an extended time. This facilitates analysis of faults.

Functioning method: The window opens automatically, when a new fault alarm occurs. The corresponding combined alarm flashes in the menu bar when there is a new fault alarm (e.g. E flashes red => there is a new emergency stop). Press the Reset Button to acknowledge fault alarms. When the fault alarm is no longer pending, the text is cleared from the display. If a fault stops the machine is not reset it is red otherwise yellow. If a less critical fault is not reset it is grey otherwise white. Press the Home Button to exit the fault alarm window. The fault alarm window does not open again until a new fault alarm occurs or it is selected via the E, S, A buttons.

The fault alarms are stored in a separate list. There are also some plant-specific alarms which are displayed there. The list is printed for the relevant project.

There are two important groups of faults in the fault alarm overview. The first group consists of automatically acknowledged faults. These faults are automatically reset and delete from the fault alarm overview after the cause is rectified. The second group consists of faults which can only be reset after rectification when the user presses the reset button (on the switching cabinet or the fault alarm page).

Fault alarms which activate the emergency stop chain can only be acknowledged with a hardware reset (button on the MMC switching cabinet).

The source column only applies for multi-module plants and central fault histories, as it contains the module numbers to indicate the module affected by the fault. If there are so many faults that they cannot all be shown in the table, you can scroll up and down using the arrow keys right and left of the table.

The alarm log allows you to view faults which have already been rectified!

5.16. System Status Indications This screen provides an overview of all pending status indications (cooling water pump on, generator switch off, …). The screen layout is identical to that of the fault alarms. All active status indications are displayed (highlighted in green). The optional alarm log can also be opened.


5.17. Alarm log

You can switch to the window that displays the fault history using the alarm log button in the fault alarm window or system status indication window. When you switch to the alarm log page, the fault database is searched and the occurrence and cessation of faults in previous 24 hours are displayed. If a fault has stopped, the fault alarm is displayed along with “gegangen” (stopped). The source column only applies for multi-module plants and central fault histories, as it contains the module numbers to indicate the module affected by the fault. If not all the faults fit in the table, you can scroll up and down using the arrow keys on the right side of the table. Start button: Use the Start button to begin a new search. Filter button: Use the filter button to open a selection window in which you can set the criteria for searching the database.


There are four filter criteria. If the colour changes to green, a criterion is active. Message type: You can select whether you want to list only the fault alarms (AM), only system status indications (SM) or both message types (AM + SM). The default setting is fault alarm. Kind: You can select whether you want to display a fault occurrence, fault cessation or both. Both are indicated by default. Alarm number: If you are only searching for the occurrence of a specific alarm, you can activate the alarm number search using the Nb.-Search button. You must also enter the number you are searching for in the field below. You can also select up to 4 numbers. Click Default to reset the number. Days: By default, the database search begins with the previous day. You can set the upper field to search the database for older results. The highest value is 31 days. The value of the second field must always be 1. If you are searching for results within a certain time period, for example, 10 and 20 days prior, you must also change the value in the second field. The value of the second field must always be larger than the value in the first field; however, the value cannot exceed 31. Number: The frequency of messages is determined. This evaluation is only intended for use by operators with a higher user level. Save button: This buttons allows you to copy the current database to the D:\MDE\FileSharing directory, which is accessible to customers. Click Home to exit the alarm log window.


5.18. Power Controller

This screen gives an overview of the entire power controller. All important states and online data for the power controller are displayed on the right.

Source of the setpoint: The top line shows the operating state selected:

� Local � Remote � Via interface (SS) � Manual operation � Timer

The corresponding LED illuminates and the valid operating mode (setpoint source) is highlighted in green (e.g. flexible value).


Manual Operation: The power setpoint can also be set manually. To do so, the key switch must be set to manual and operation must be set to local. The “Manual” button lights orange after the key switch is switched. Now, a “Manual value” can also be entered and subsequently confirmed by pressing OK. Set the key switch to automatic to exit manual operation. The current valid setpoint is set again. Parameters for manual operation: Manual value % The value for manual operation set when the OK

key is pressed. Setpoint depending on the current operating mode: 1 = Module off 2 = Flexible value 3 = Setpoint 1 4 = Setpoint 2 5 = Grid feed control 6 = Gas tank control 7 = CH4 control 8 = Current operation => fixed at 100% 9 = Heat operation 10 = Heat operation (floating) 11 = Heat operation (grid feed-in limit) 12 = Heating water reservoir operation => fixed at 100% Local switching: The key switch must be set to Local. Press the corresponding button

(e.g. flexible value 1) to switch the operating mode. Remote switching (hardware): To do this, a total of four digital inputs are available with which all

operating modes can be activated using the correct combination (binary coding). Interface mode may not be active!

Switching via interface: The interface must be active and the corresponding data point must

contain the required number. Switching using the timer: The switching is time-controlled (see timer description).


Valid setpoint: Flexible value Two values are displayed: � Local: This value applies when the “Controller” key switch is set to “Local”. The setpoint can be

entered directly. � Remote: This value applies when the “Controller” key switch is set to “Remote”. The setpoint is

specified via a 4-20mA signal. The value is determined via the telegram if an interface is used for control.

Setpoint 1 (optional) Two values are displayed: � Local: This value applies when the “Controller” key switch is set to “Local”. The setpoint can be

entered directly. � Remote: This value applies when the “Controller” key switch is set to “Remote”. The value (equals

the local value) stored in the program is requested via a digital input signal. The value is determined via the telegram if an interface is used for control.

Setpoint 2 (optional) Two values are displayed: � Local: This value applies when the “Controller” key switch is set to “Local”. The setpoint can be

entered directly. � Remote: This value applies when the “Controller” key switch is set to “Remote”. The value (equals

the local value) stored in the program is requested via a digital input signal. The value is determined via the telegram if an interface is used for control.

Grid feed control (optional) When the grid feed control mode is active, the current setpoint comes from the grid feed control (see additional functions). Gas Tank (optional) When the gas tank mode is active, the current setpoint comes from the gas tank control (see additional functions). CH4 Regulation (optional) When the CH4 control mode is active, the current setpoint comes from the CH4 control (see additional functions). Current operation (optional) When the heating water reservoir mode is active, the setpoint is set to 100%. Heat operation (optional) When the heat operation mode is active, the current setpoint comes from the heating control (see additional functions). Heat operation floating (optional) When the heat operation floating mode is active, the current setpoint comes from the heating control (see additional functions). Heat operation with grid feed-in limit (optional) When the heat operation with grid feed-in limit mode is active, the current setpoint comes from the heating control (see additional functions). Heating water reservoir (optional) When the heating water reservoir mode is active, the setpoint is set to 100%. The settings are

shown in the heating water reservoir operation (see additional functions).


Power reduction: Displays whether power reduction is active. Reduction can be triggered by various factors: Knocking signal The MTU motor management reduces power by knocking. This kind of reduction is indicated. Gas change (optional) Power is reduced to a set value during the gas change. This value may even fall below the minimum load of the module.


5.19. Start / Stop Procedure

The start or stop procedure can be observed in this screen. The individual start phases are activated when the module starts. Manual operation can also be implemented from this page. Manual Operation:

� Key switch set to Local � Key switch set to Manual � Activate start request locally (switch) � The engine starts and stops at phase 3 (synchronization not initiated) � In the idle state, the speed can now be adjusted locally using the higher / lower keys � Press the Synchronization button to start synchronization. Synchronization must also be enabled by

MTU motor management (digital input signal) � The power can be preset when the generator switch is closed. It is automatically set to 10% on

activation. There are two ways of changing the power: � Using the higher / lower keys and the corresponding typing value. � Using a manually entered setpoint and the OK key.

Parameters for manual operation: Typing value % The setpoint is changed by the typing value every

time an arrow key is pressed. Manual value % The value for manual operation set when the OK

key is pressed.


5.20. Counter reading

Some of the counter readings are optional (gas quantity, current counter, heat quantity, steam, reserve). These counters are evaluated using a pulse signal. The pulse value is cumulated for each pulse. This is set in the module parameters.

Setting the counter readings You can enter a desired counter reading value using the “Setpoint” input field. When you press the “Reset Button” of a counter, the entered value is changed to the current counter reading for this counter.

The following page is opened when you press the Backup button:

A backup of the previous 365 days with the date for the most important operating values is stored.


5.21. Overview of Auxiliary Features

Use the corresponding buttons as in the main menu to call up the individual sub-functions. Unavailable functions are grayed out and cannot be selected.

5.22. Cleaning Window

The screen can be cleaned easily when this screen is open, as no operating elements are displayed. Only one element (home button) changes the display.


5.23. Additional Function: Water Temperature Controller (optional)

The controller is a PI controller whose initial size can be set by the regulation valve from fully closed (0%) to fully open (100%). Control reaction: Actual value > Setpoint => The control valve closes (until the minimum opening permitted at most). Direction: However, if the control valve does not match this direction, you can change the setting via a module parameter. Two types of actuator can be used for the temperature controller: � Analog actuator (standard: 0 to 10V) � Actuator with open/closed pulses (with limit positions)

Manual operation can be used for both actuators. Manual operation is reset when the module is restarted.

Special feature of actuators with open/closed pulses and limit positions: Each time the overtravel time elapses, a reference stroke is initiated. This allows the runtime of the valve to be determined and the setting position of the control valve can always be determined via the pulse/pause ratio. The reference stroke can also be activated manually using the “Start reference stroke” button in the idle state. Reference strokes cannot be cancelled once they have been started.


Temperature controller parameters: Setpoint °C This parameter is the same as the setpoint for the controller. After the

start-up gradient, the controller adjusts the temperature to this value. Starting setpoint

°C The start gradient (for the temperature) is started from this value.

Warm-up time sec The start gradient is increased from the start setpoint to the actual setpoint over this time.

Overtravel time sec When the controller is deactivated, there is an overtravel time. KP Proportional share of the controller. Per °C deviation, the variable is

opened or closed by this factor (e.g. standard deviation +5°C, KP=6=> Proportional share of the variable is 30%.). The KP can be set differently for normal operation and the warm-up time!

Ki Integral share of the controller. If standard deviation remains, the Ki value is added to the P share every time the adjustment time (Tn) expires. A large Ki value can cause the setting for the regulation valve to fluctuate.

Tn sec The adjustment time serves to calculate the I proportion. The starting value of the I controller is added to the starting value of the P controller in these time intervals. An inadequate adjustment time can cause the setting for the regulation valve to fluctuate. The Tn can be set differently for normal operation and the warm-up time!

Permitted opening

% When running, the valve can only be closed or opened (depending on the direction) to the angle of opening entered here.

Manual correcting variable

% When manual operation is active, this setpoint is output to the regulation valve.

Additional parameters for three-level controllers: Pulse/pause time

ms A pulse (open or close) is sent for the time set. The same pause time elapses after each pulse. For example, if you have a valve with a running time of 130 seconds (from open to closed) and you set a time of 1300ms, then a correcting variable change of 1% per pulse would result. The running time is determined by a reference stroke for regulation valves with limit positions.


5.24. Additional Function: Mixture Water Controller (optional)

This function allows you to adjust the mixture water for the engine to a defined setpoint. Control reaction: Actual value > Setpoint => The control valve opens (until the permitted opening set at most).

This controller functions in the same way as the water temperature controller.

5.25. Additional Function: Mixture fan and pump (optional) This function cools the mixture water (re-cooler). Version 1: Cooler via level switching:

The number of existing levels is determined by a module parameter. A maximum of 2 levels are available. A level is only one switching point. This can also mean that a star/triangle-connected fan is set up with two levels. You can switch between the individual levels using the arrow keys. The current parameters are displayed for the selected level (no.). If a level is running, a green LED illuminates. Each level can also be operated manually. Manual operation is indicated by an illuminated orange LED. The function of each individual level can be defined using the following four parameters. Parameters for re-cooler levels: Startup value °C When the actual temperature value exceeds this limit, the

cooler level is activated after the switch on delay. Switch on delay sec Switch on delay for the cooler level. Shutdown value °C When the actual temperature value falls below this limit, the

cooler level is deactivated after the switch off delay. Switch off delay sec Switch off delay for the cooler level.

Pump: The mixing pump is activated immediately with auxiliary drives. The pump can also be operated manually when idle.


Version 2: Cooler via frequency converter: In progress!!!

In this version, the re-cooler fans are controlled via a frequency converter. A PI controller is used for this to output the setpoint (0-10V) to the frequency converter. The setpoint can otherwise only be set manually.

Parameters for frequency converters: The control parameters of the PI controller are identical to those of the water temperature controller. However, there are no warm-up and overtravel times. Pump: The mixing pump is activated immediately on activation of the auxiliary drives. The pump can also be operated manually when idle.


5.26. Additional Function: Emergency Cooling Water Controller (optional)

This function allows you to adjust the coolant circuit for the engine to a defined setpoint. Control reaction: Actual value > Setpoint => The control valve opens (until the permitted opening set at most).


5.27. Additional Function: Emergency cooler fan and pump (optional) Version 1: Emergency cooler fan via level switching

Emergency cooler fan: The number of existing levels is determined by the option parameters. A maximum of 12 levels are available. A level is only one switching point. This can also mean that a star/triangle-connected fan is set up with two levels. You can switch between the individual levels using the arrow keys. The current parameters are displayed for the selected level (no.). If a level is running, a green LED illuminates. Each level can also be operated manually. Manual operation is indicated by an illuminated orange LED. The function of each individual level can be defined using the following four parameters. Parameters for emergency cooler levels: Startup value °C When the actual temperature value exceeds this limit, the

emergency cooler level is activated after the switch on delay. Switch on delay sec Switch on delay for the emergency cooler level. Shutdown value °C When the actual temperature value falls below this limit, the

emergency cooler level is deactivated after the switch off delay. Switch off delay sec Switch off delay for the emergency cooler level.

Emergency cooler pump: The emergency cooler pump can also be set with a series of parameters like the fan levels. The pump can also be operated manually. Parameters for emergency cooler pump: Startup value °C When the actual temperature value exceeds this limit,

the pump is activated after the switch on delay. Switch on delay sec Switch on delay for the pump. Shutdown value °C When the actual temperature value falls below this limit,

the pump is deactivated after the switch on delay. Switch off delay sec Switch off delay for the pump.


Version 2: Emergency cooler fan via frequency converter:

In this version, the emergency cooler fans are controlled via a frequency converter. Up to 2 frequency converters can be used. One PI controller is used for each to output the setpoint (0-10V) to the frequency converter. The setpoint can otherwise only be set manually. However, if 2 frequency converters are used, there is only one setpoint!

Parameters for frequency converters: Setpoint °C This parameter is the same as the setpoint for the controller. Startup value % or °C When the limit value is reached, the frequency converter is enabled.

System dependent: e.g. activation via the position of an emergency cooling control valve (%) or based on the water temperature (°C). If 2 frequency converters are used, the second FC is enabled based on the correcting variable of the first FC!

Shutdown value

°C If the value falls below the limit, the frequency converter is deactivated.

Relief value % When the frequency converter is deactivated, this value is passed to the emergency cooling valve as a setpoint. This is to smooth the switching process. If 2 frequency converters are used, this value is assigned to the first FC as a correcting variable!

KP Proportional share of the controller. Per °C of deviation, the correcting variable is increased or decreased by this factor (e.g. standard deviation +5°C, KP=6=> Proportional share of the variable is 30%).

Ki Integral share of the controller. If standard deviation remains, the Ki value is added to the P share every time the adjustment time (Tn) expires. A large Ki value can cause the setting for the frequency converter to fluctuate.

Tn sec The adjustment time serves to calculate the I proportion. The starting value of the I controller is added to the starting value of the P controller in these time intervals. An inadequate adjustment time can cause the setting for the frequency converter to fluctuate.


% When manual operation is active, this setpoint is output to the frequency converter.


5.28. Additional Function: Room Temperature Controller (optional)

This function allows you to adjust the room temperature to a defined setpoint. The flap control (incoming air, outgoing air, circulation air) must be wired to the hardware so one input signal (e.g. 0 to 10V) adjusts all flaps to the correct position. Control reaction: Actual value > Setpoint => The control valve opens (until the permitted opening set at most).


5.29. Additional Function: Room Air Fan Control (optional) Version 1: Room fan via level switching:

The number of existing levels is determined by a module parameter. Up to 4 levels are available (incoming and outgoing air). A level is only one switching point. This can also mean that a star/triangle-connected fan is set up with two levels. You can switch between the individual levels using the arrow keys. The current parameters are displayed for the selected level (no.). If a level is running, a green LED illuminates. Each level can also be operated manually. Manual operation is indicated by an illuminated orange LED. The function of each individual level can be defined using the following four parameters. Parameters for room air fan levels: Startup value °C When the actual temperature value exceeds this limit, the room

air fan level is activated after the switch on delay. Switch on delay sec Switch on delay for the room air fan level. Shutdown value °C When the actual temperature value falls below this limit, the

room air fan level is deactivated after the switch off delay. Switch off delay sec Switch off delay for the room air fan level.

If the fan is activated by a thermostat (e.g. 2 level), the parameters have no function. Optional: All fan levels are always activated if there is a gas pre-alarm. The fans are deactivated for

main gas alarms.


Activation of the room fan (adjustable): The "Enable room fan" button allows the fans to be enabled as required.

The following combinations are possible: Enable even when the system is idle => The fans are switched on when the value exceeds the limit even if the machine is idle. Enable only when the system is running => The fans are only enabled when the machine is running and the value exceeds the limit. Level 1 immediately on operation => This option can also be activated in addition to the two versions specified above. The first fan level is then activated immediately when the motor is started (regardless of the limit value).


Version 2: Room fan via frequency converter:

In this version, the room fans (incoming / outgoing air) are controlled via a frequency converter. One PI controller is used for each to output the setpoint (0-10V) to the frequency converter. The setpoint can otherwise only be set manually.

Parameters for frequency converters: Setpoint °C This parameter is the same as the setpoint for the controller. Idle state offset °C When the machine is idle, this value is added to the setpoint. This

prevents constant activation/deactivation when idle, while still dissipating built-up heat.

Startup value °C This value is added to the setpoint. If the room temperature exceeds the limit value, the FC is enabled.

Shutdown value

°C This value is subtracted from the setpoint. If the room temperature is less than the total value, the FC is deactivated again.

KP Proportional share of the controller. Per °C of deviation, the correcting variable is increased or decreased by this factor (e.g. standard deviation +5°C, KP=6=> Proportional share of the variable is 30%.).

Ki Integral share of the controller. If standard deviation remains, the Ki value is added to the P share every time the adjustment time (Tn) expires. A large Ki value can cause the setting for the frequency converter to fluctuate.

Tn sec The adjustment time serves to calculate the I proportion. The starting value of the I controller is added to the starting value of the P controller in these time intervals. An inadequate adjustment time can cause the setting for the frequency converter to fluctuate.

Permitted opening

% In operation, the correcting variable output cannot be less than this value.


% When manual operation is active, this setpoint is output to the frequency converter.


5.30. Additional Function: CH4 Regulation (optional)

The CH4 controller is divided into several sections: � Start release of the engine based on the CH4 content (digital contact or limit value via analog actual

value signal). � Power limitation based on the CH4 content (only works if an analog actual value signal is available)

All functions are only active in automatic operation!

Start release via digital contact: This module is released or blocked depending on the CH4 content. To do so, a digital sensor is queried. The following parameters are made available: Switch on delay sec When the contact is triggered, this time elapses. The module is not

released until this time has elapsed and the corresponding signal is received.

Switch off delay sec When the contact is deactivated, this time elapses. The module is not blocked until this time has elapsed and the corresponding signal is received.


Start release via analog signal - optional: This module is released or blocked depending on the CH4 content. An analog actual value signal is queried and compared with the limit values. The following parameters are made available: Switch on CH4 content

% The switch on timer starts when the actual value exceeds this limit.

Switch on delay sec This time elapses when the value exceeds the limit. The module is not released until this time has elapsed and the limit value is exceeded.

Switch off CH4 content

% The switch on timer starts when the actual value falls below this limit.

Switch off delay sec This time elapses when the value falls below the limit. The module is not blocked until this time has elapsed and the value falls below the limit.

The customer must determine the curve. Power limitation via analog signal: The power of the engine is limited based on the CH4 content. An analog actual value signal is queried and compared with the limit values. The following parameters are made available: Min. at CH4 content % The lowest power level is assigned to this CH4 value. Power at min. % The power is limited to this value when the CH4 value falls below

the min. limit. The limit is calculated via a straight line between the minimum and maximum value.

Max. at CH4 content % The highest power level is assigned to this CH4 value. Power at max. % The power is limited to this value when the CH4 value exceeds the

max. limit. The limit is calculated via a straight line between the minimum and maximum value.

Values can only be modified from a certain user level (service).


5.31. Gas Tank (optional)

The gas tank controller is divided into several sections: � Start release of the engine based on the fill level/gas pressure (digital contact or limit value using an

analog actual value signal) � Power limitation based on the fill level/gas pressure (digital contact or limit value using an analog

actual value signal)

All functions are active in automatic operation only.

The evaluation is carried out either via an analog signal (standard) or digital signals (3 contacts). A combination is not useful and therefore not possible!

The customer must determine all parameters.

Gas tank (fill level/pressure): Start release using a digital contact: This module is released or blocked depending on the fill level/pressure. Two digital sensors are queried. The following parameters are available: Switch-on delay sec When the contact is triggered, this time elapses. Once this time

elapses, the module is released and the corresponding signal is received.

Switch-off delay sec When the contact is triggered, this time elapses. Once this time elapses, the module is blocked and the corresponding signal is received


Gas tank (fill level/pressure): Start release using an analog signal: This module is released or blocked depending on the fill level/pressure. An analog actual value signal is queried and compared with the limit values. The following parameters are available: Startup value % The switch-on timer starts when the actual value exceeds this

limit. Switch-on delay sec This time elapses when the value exceeds the limit. Once this

time elapses, the module is released and the limit value is exceeded.

Shutdown value % The switch-on timer starts when the actual value falls below this limit.

Switch-off delay sec This time elapses when the value falls below the limit. Once this time elapses, the module is blocked and the value falls below the limit.

Gas tank (fill level/pressure): Power limitation using digital contacts Engine power is limited based on the fill level/pressure. To do so, a third switch is read (off, on & max. power value, min. power value). The following parameters are available: Power at max. % When the switch is triggered (on & max. power value), the

power is set to this setpoint. Power at min. % When the switch is triggered (min. power value) and the on &

max. power value switch is not active), the power is set to this setpoint.

Gas tank (fill level/pressure): Power limitation using an analog signal: Engine power is limited based on the fill level/pressure. An analog actual value signal is queried and compared with the limit values. The following parameters are available: Min. fill level/pressure at % The lowest value of the power value is assigned to this fill

level/pressure value. Power at min. % If the fill level/pressure falls below the min. limit, the power is

limited to this value. The limit is calculated using a straight line between the minimum and maximum value.

Max. fill level/pressure at

% The highest power value is assigned to this fill level/pressure value.

Power at max. % If the fill level/pressure exceeds the max limit, the power is limited to this value. The limit is calculated using a straight line between the minimum and maximum value.

Gas tank (fill level/pressure): Torch release using an analog signal: The torch is released or blocked depending on the fill level/pressure. An analog actual value signal is queried and compared with the limit values. The following parameters are available: Startup value % The switch-on timer starts when the actual value exceeds this

limit. Switch-on delay sec This time elapses when the value exceeds the limit. Once this

time elapses, the torch is released and the limit value is exceeded.

Shutdown value % The switch-on timer starts when the actual value falls below this limit.

Switch-off delay sec This time elapses when the value falls below the limit. Once this time elapses, the torch is blocked and the value falls below the limit.


5.32. Grid feed control (optional)

There are three ways of controlling the grid transfer power: � Plant draws power from grid. � Plant supplies power to grid. � The load is regulated to zero at the grid transfer station (no-load regulation).

The actual value signal at the grid transfer station is a “+/- signal” (e.g. -2000 kW to +2000 kW). The signal is evaluated as follows: � Generator power < consumer power => signal is positive (+) => plant draws power from grid � Generator power > consumer power => signal is negative (-) => plant supplies power to grid � Generator power = consumer power => signal is zero => plant neither draws power from grid nor

supplies power to grid One can also set a start release of the module based on the grid transfer power. The engine is only released when the configurable switch on threshold has been exceeded. The same applies to the switch off threshold. This allows the system to be used ideally, so that no peak currents must be paid for.

All functions are active in automatic operation only!

When using the two functions (grid feed control and start release), you must ensure that they do not cancel each other out (e.g. the grid feed control is set to adjust to a value which is evaluated as a deselection point of the system).


Status indications: � No-load regulation active.

This indicates when grid feed control is activated. � Plant supplying to grid.

This indicates when the plant is supplying to the grid. � Plant drawing from grid.

This indicates when the plant is drawing from the grid. � Controller dead zone active

This indicates when the deviation is less than the dead zone. � Maximum setpoint reached

This indicates when the setpoint calculated has reached the maximum permitted setpoint for the power controller. The maximum setpoint (%) is shown in the power controller parameters. The setpoint is specified in the module parameters and cannot be changed.

� Minimum setpoint reached This indicates when the setpoint calculated has reached the minimum permitted setpoint for the power controller. The minimum setpoint (%) is shown in the power controller parameters. The setpoint is specified in the module parameters and cannot be changed.

� Start release If the setpoint/actual value deviation is negative, the plant supplies power to the grid. If the deviation is positive, the plant draws power from the grid.


Parameter for the grid feed control: Setpoint KW The power is adjusted to this value at the grid transfer station. If the value is

negative, the plant must supply power to the grid. Dead zone KW If the deviation (xd) is less than this value, the setpoint for the power controller is

not changed. This prevents the system fluctuating. Increment KW This value specifies how many percent the setpoint for the power controller is

changed each second. The setpoint for the power controller is only changed if the deviation is greater than the dead zone. The increment value set must be less than the dead zone value.

Pause time sec This is the pause time between two changes of the setpoint for the power controller.

Parameters for start release: X1 KW Selection without delay. The engine is released immediately when

the actual value exceeds this limit. X2 KW Delayed selection. The engine is released after a delay time when

the actual value exceeds this limit and is less than the switch on without delay value. The delay time is calculated on a straight line between the undelayed and delayed switch on value.

Y1 sec Delay time for the selection. This time is calculated on a straight line between the undelayed and delayed switch on value. The closer the current actual value is to the switch on without delay value, the shorter the delay time.

X3 KW Delayed deselection. The engine is blocked after a delay time when the actual value falls below this limit. The delay time is calculated on a straight line between the undelayed and delayed switch off value.

X4 KW Deselection without delay. The engine is blocked immediately when the actual value falls below this limit.

Y2 sec Delay time for deselection. This time is calculated on a straight line between the undelayed and delayed switch off value. The closer the current actual value is to the switch off without delay value, the shorter the delay time.

The limit values for selection/deselection must decrease from left to right (on the x-axis). If this is not

observed, a default value is activated (+400, +300, -300, -400).


5.33. Exhaust / Bypass Butterfly Valve Control (optional)

The exhaust flap is opened when the module starts. It is required for multi-module plants to prevent back-flows of combustion air into the deselected modules. The bypass flap is intended to channel the hot exhaust gas past the exhaust gas heat exchanger with little heat absorption to prevent the heating water overheating. Bypass operation can be activated via a configurable limit value or manually using the selection button. Bypass operation can also be activated remotely via an optional input. Flap 2 is opened, and flap 1 is closed after the “Open” limit switch is triggered. All flaps can also be operated manually. Parameters for bypass operation: Bypass operation limit value °C When the value exceeds the limit, bypass flap 2 opens and

then bypass flap 1 closes. Hysteresis for bypass operation:

°C When the value falls below the limit by the hysteresis, bypass operation is deactivated.

All functions are active in automatic operation only!


5.34. Heat operation motor (optional) Start release is based on a water temperature only:

The module is stopped or started automatically when the temperature exceeds/falls below various limits. Delay times can also be entered. All limit values can also be shifted via the external temperature or a reduction.

All functions are active in automatic operation only! Parameters for a stat request: Selection without delay X1

°C The engine is released immediately when the actual value falls below this limit.

Delayed selection X2

°C The engine is released after a delay time when the actual value falls below this limit and is greater than the switch on without delay value. The delay time is calculated on a straight line between the undelayed and delayed switch on value.

Delay time for the selection Y1

sec This time is calculated on a straight line between the undelayed and delayed switch on value. The closer the current actual value is to the switch on without delay value, the shorter the delay time.

Deselection without delay X4

°C The engine is blocked immediately when the actual value exceeds this limit.

Delayed deselection X3

°C The engine is blocked after a delay time when the actual value exceeds this limit and is less than the without delay limit value. The delay time is calculated on a straight line between the undelayed and delayed switch off value.

Delay time for deselection Y2

sec This time is calculated on a straight line between the undelayed and delayed switch off value. The closer the current actual value is to the switch off without delay value, the shorter the delay time.


Floating: Start release and output control are based on a water temperature:

The controller is a PI controller whose initial size can be changed by the output of the module from 50% (min. setpoint) to 100%. The limit values for the start release can be influenced using the external temperature curve.

All functions are active in automatic operation only.


Example with heating water return flow temperature as the setpoint variable:

� Start release (value correspond to the current illustration above): If the module is idle and the heating water return flow temperature (actual value) drops below 66°C (X2 in illustration), then the module is activated after 30 seconds (Y2 in illustration). The more the temperature drops (direction X1), the faster the module is activated. � Controller (value correspond to the current illustration above): If the module is running, the setpoint power is determined based on the heating water return flow temperature in the PI control. The current actual temperature value is also displayed. An attempt is made to adjust the heating water return flow temperature to the “Setpoint” (70°C in the example), i.e. until the heating water actual value is less than the heating water setpoint; the module power setpoint (setpoint power) is increased according to the controller parameters (up to max. 100%). If the heating water actual value exceeds the heating water setpoint, the module power setpoint is reduced again (to setpoint min). Special “Heat operation with limit function” feature: In this mode, the calculated setpoint is limited by the grid feed control. Unlike the current calculated setpoint of the grid feed control, the setpoint is not increased further. � Shutting down (start release is deactivated): When the heat controller registers the “Setpoint min” and the “Heating water temperature > limit value 1” fault alarm is pending, the module is deactivated. This results in the longest possible service life of the module. Displaying the output control Control active This LED turns green as soon as the control has been activated (start

release active through heat operation and grid parallel operation). Warm-up time This LED turns green while the start-up gradient is active and the warm-

up time expires Setpoint min This LED turns green as soon as the calculated module setpoint power

equals the "Setpoint min". 100% This LED turns green as soon as the calculated module setpoint power

equals the setpoint max and 100%. Grid feed control If no grid feed control is present, this display is deactivated.

During limited heat operation, this LED turns green as soon as the output of the grid feed control is less than the output of the floating heat operation. Below the LED, the calculated output of the grid feed control is also displayed.

Setpoint °C The current heating water temperature setpoint is displayed here. The heating water temperature is increased from the start setpoint to the setpoint during the warm-up time.

Actual value °C The current actual value for the heating water temperature is displayed on the temperature sensor.

Setpoint/actual value deviation Deviation

°C The difference between the setpoint and the actual value is displayed here (setpoint – actual value).

Setpoint power % The module setpoint power is displayed here. Actual value power

% The module actual power value is displayed here.


Parameters for output control: Setpoint °C This parameter is the same as the controller setpoint (heating water

temperature). After the start-up gradient, the controller adjusts the heating water temperature to this value via the module output.

Start setpoint °C Once the controller is activated, the setpoint temperature is increased by one start-up gradient. This setpoint gradient (for the temperature setpoint) is started from this value.

Warm-up time sec The temperature setpoint is increased from the start setpoint to the actual setpoint during the warm-up time. This means that after this time has expired, the entered “setpoint” is adjusted to the temperature value.

KP Proportional share of the controller. Per °C deviation, the variable (module power setpoint) is opened or closed by this factor (e.g. standard deviation +5°C, KP=6=> Proportional share of the variable is 30%.).

Ki Integral share of the controller. If standard deviation remains, the Ki value is added to the P share every time the adjustment time (Tn) expires. A large Ki value can cause the setting for the module power to fluctuate.

Tn sec The adjustment time serves to calculate the I proportion. The starting value of the I controller is added to the starting value of the P controller in these time intervals. An inadequate adjustment time can cause the setting for the module power to fluctuate.

Setpoint min % Equals the minimum power upon which the module can be operated


5.35. Heat operation boiler (optional)

The boiler is stopped or started automatically when the temperature exceeds/falls below various limits. Delay times can also be entered. All limit values can also be shifted via the external temperature or a reduction.

All functions are active in automatic operation only! Parameters for a stat request: Selection without delay X1

°C The boiler is released immediately when the actual value falls below this limit.

Delayed selection X2

°C The boiler is released after a delay time when the actual value falls below this limit and is greater than the switch on without delay value. The delay time is calculated on a straight line between the undelayed and delayed switch on value.

Delay time for the selection Y1

sec This time is calculated on a straight line between the undelayed and delayed switch on value. The closer the current actual value is to the switch on without delay value, the shorter the delay time.

Deselection without delay X4

°C The boiler is blocked immediately when the actual value exceeds this limit.

Delayed deselection X3

°C The boiler is blocked after a delay time when the actual value exceeds this limit and is less than the without delay limit value. The delay time is calculated on a straight line between the undelayed and delayed switch off value.

Delay time for deselection Y2

sec This time is calculated on a straight line between the undelayed and delayed switch off value. The closer the current actual value is to the switch off without delay value, the shorter the delay time.


5.36. External temperature shift (optional) The external temperature shift can be used for the heating operation (motor and boiler). This function influences the switching point for the release.

An offset (positive or negative) is calculated via the curve using the current external temperature, which is then added to the switching points. The shift can be adjusted for conditions via three gradients. 4 sets of parameters are required for this.

The limit values for the x-axis (external temperature limit values) must increase from left to right. The limit values for the y-axis (offset limit values) must increase from top to bottom.

The switching points can also be shifted down by a set value via a decrease (activated via an optional input). Parameters for the external temperature: X1 °C External temperature value for offset value Y1 Y1 °C Offset value for external temperature value X1 X2 °C External temperature value for offset value Y2 Y2 °C Offset value for external temperature value X2 X3 °C External temperature value for offset value Y3 Y3 °C Offset value for external temperature value X3 X4 °C External temperature value for offset value Y4 Y4 °C Offset value for external temperature value X4

Parameter for decrease: Decrease value °C All switching points are shifted downward by this value.


5.37. Heating Water Reservoir (optional)

The module is started or stopped by a water reservoir controller. For this, 4 sensors in the water reservoir are evaluated. This screen shows whether the buffer is being filled or emptied. A set heat-up time begins when the module is released for startup. After this timer has elapsed, further heat generators (e.g. boiler) are released for activation. However, if the gradient evaluation system detects that the buffer is already being refilled, no other heat generators can be selected.

All functions are active in automatic operation only! Parameters for the water reservoir: PT4: Selection without delay °C The engine is released immediately when the actual value

falls below this limit. The reservoir is empty. PT5: Delayed selection °C The engine is released after a delay time when the actual

value falls below this limit (see delay time). PT5: Delay time for the selection

sec This timer starts when the value for PT5 falls below the limit. The engine is released after the timer has elapsed.

PT7: Deselection without delay

°C The engine is blocked immediately when the actual value exceeds this limit. The reservoir is full.

PT6: Delayed deselection °C The engine is blocked after a delay time when the actual value exceeds this limit and is less than the limit value for PT7 (see delay time).

PT6: Delay time for deselection

sec This timer starts when the value for PT6 exceeds the limit. The engine is blocked after the timer has elapsed.

Warm-up time min. Further heat generators can be released after the warm-up time has elapsed.

Parameters for the gradient: Time °C Time in which between a temperature difference has been

measured to see if the reservoir is filled or emptied. If the reservoir is filled no more heat generator is released

Temperature sec Temperature difference which has to be recognized to see if the reservoir is filled or emptied.


5.38. Additional Function: Timer (optional)

The operating characteristics of the system can be influenced at certain times of the day or weekdays using the timer.

A maximum of 5 operating modes can be activated on a system!

Operation: In the top half of the menu, you can see the weekdays with the currently set operating modes at certain times of day. The various operating modes are displayed in colour. A maximum of 8 switching points can be set per day. Below the weekdays, you can see the key of the available operating modes. At the very bottom right side, you can see the current operating mode. You can select the following functions using the three buttons below on the left:

1. Time program: The timer controls the operating modes of the system. 2. Always on: The timer program is deactivated. The module is always released. 3. Always off: The timer program is deactivated. The module is blocked.


Setting a switching point for a weekday: To set a switching point, you must click the bar of the desired weekday. An entry window opens.

On the left side, you can see the activated switching points with the corresponding selected operation mode. Deleting a switching point: If you would like to delete a switching point, press “Delete”. Adding a switching point (max. 8): To enter a new switching point, you must click “h” and “min”. Then click the corresponding Operating mode (colour keys) and “Accept”. This is how you add the required switching point for the day.

To activate the set value, press “Save!”. The button is only active if the data has been changed.

To reach the overview again, click in the middle of the screen.


5.39. Additional Functions: SMS/e-mail (optional)

This function allows you to send a message by e-mail should faults or system status indications occur. These e-mails accumulate on the MDE server and are then forwarded to the entered customer addresses. The automatic maintenance request can also be indicated.

When transferring messages by e-mail, all currently active messages are summarised and sent per e-mail. All active messages are individually sent to the SMS recipients (due to character lengths). You should therefore be very careful when selecting the messages to be sent (also due to accumulating costs).

Requirements:

See separate document: "Message service technical description" Transferring operating data (optional additional function): Once a day, the most important operating data (e.g. operating hours, startup counter, miscellaneous counter statuses, overview of the cumulative fault alarms, etc.) are automatically sent via MDE per e-mail.

The operating data cannot be transferred per SMS, since the text document is considerably long! Operation: Overview window

The first text field in the overview window displays the collected SMS messages to be sent, and the second text field displays the messages to be sent per e-mail. The third text field records the send status. If the pending messages are processed and sent, they are deleted from the first two text fields. This also occurs when messages cannot be sent, for example, when remote data transmission to the Internet provider cannot be established. Successful and failed send attempts are also recorded in the status window. This window is deleted every day at midnight. The buttons at the lower end of the overview window allow you to configure the SMS/e-mail client.


Operation: Selecting system status indications for notification

Click the system status indication button in the overview window to open the page where you can set message options for system status indications. In the first column, you can see whether or not the corresponding system status indication is selected for notification by SMS. If the message is selected, the box is highlighted in green and Yes is displayed. When messages are not selected, the corresponding box is white and No is displayed. In the second column, you can select the corresponding system status indication to be sent by e-mail. To change your selection, select the corresponding box. You can only make changes if you have logged into the main operation menu. Use the four buttons on the right table margin to move the contents of the table up and down to process all the messages. Operation: Selecting fault alarms for notification See selecting the system status indications!

5.40. Service menu

This menu is intended for service purposes only. The menu can only be opened by authorized personnel.


5.41. External Communication (optional)

The active communication protocol is indicated. The current status of communication is also displayed. This can be helpful when troubleshooting. The parameter window opens when you click the active communication protocol (e.g. Modbus).

All parameters used are shown in this window. This window allows you to change the address, for example. Press the “Save” button to activate the data.


You can open a simulation window for testing. To do so, press the “Simulation” button.

When activated, the simulation intervenes directly with the data transfer between the MMC and the connected remote control.

Press the “Active” button to start the simulation. The data areas from the controller selected for simulation are replaced with the data selected in the simulation window. Attention: Once testing is completed, the simulation must be deactivated using the “Active” button. After 120 minutes, the simulation is automatically switched off. Simulation of output data => data sent to the external interface (status)

� Select the bit information to be simulated using the interface description � Enter status no. required (e.g. fault alarms 1-16) � Set or reset the required bits (e.g. set fault alarm 7) � Tests can be carried out at the remote station to determine whether the signal is received correctly

When simulating analog values, the status number of the value required (see interface description) must also be entered. You can then enter the simulation setpoint. Checking the input data => data received by the external interface (controls) If the data received by the MMC is to be tested, only the control number must be entered. The corresponding bit pattern or the equivalent analog value is then displayed.


5.41.1. Interface protocol: general notes The module control can be equipped with various interface protocols (e.g. profibus DP). The corresponding interface modules must be installed in the MMC for connecting to the peripherals. The data protocol is the same for all interface protocols. All data (temperatures, fault alarms, system status indications, etc.) are available in this protocol. Communication interfaces are prepared for bi-directional operation.

See separate description


5.42. M-Graph: Single channel intraday

You can graphically display all available measuring values using this online recorder. A maximum of 60 channels are displayed. All values are updated every minute. Selecting channels: The channels can be selected by pressing “Back” or “Forward”. You can also enter the channel number

directly. Press , to determine the channel number (all numbers with the channel designation are displayed). Display range of the time axis (X): The time axis is always 24 hours. It is possible to go back for 30 days. Scaling the measuring ranges (Y): The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using two parameters. You can improve the visual resolution in the desired measuring range using these parameters. Activating: The channels are automatically saved in the database (time period over 30 days).


5.43. M-Graph: Single channel

You can graphically display all available measuring values using this online recorder. A maximum of 60 channels are displayed. All values are updated every minute. Selecting channels: The channels can be selected by pressing “Back” or “Forward”. You can also enter the channel number

directly. Press , to determine the channel number (all numbers with the channel designation are displayed). Display range of the time axis (X): The time axis can be set to 5 display ranges (1 hour/10 hours/1 day/5 days/10 days). The active range is highlighted in green. Scaling the measuring ranges (Y): The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using two parameters. You can improve the visual resolution in the desired measuring range using these parameters. Activating: The channels are automatically saved in the database (time period over 30 days).


5.44. M-Graph: System

You can graphically display eight import measuring values using this online recorder. All values are updated every minute. Selecting channels: The channels can be faded out or in by pressing their button.

Press button to see with value is aligent to which y-axis and with which scale. Press the button again to close this help. Display range of the time axis (X): The time axis can be set to 5 display ranges (1 hour/10 hours/1 day/5 days/10 days). The active range is highlighted in green. Scaling the measuring ranges (Y): The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using two parameters. You can improve the visual resolution in the desired measuring range using these parameters. Activating: The channels are automatically saved in the database (time period over 30 days).


6. Operation & display: Service menu The service menu can be accessed by authorized staff only. Use this menu to access all important control parameters. This menu also provides many tools for performing diverse tests.


6.1. System overview

All users that are active in the system are displayed in the system overview. The following functions can also be performed: � Warm/or cold starting the PLC � Enabling a configuration for MSP

Warm/or cold starting Attention: When one of the two functions is activated, the CP3485 must be restarted. This briefly shuts down the entire system. During a warm start the data remain in the RAM. During a cold start all current data are deleted.

Procedure: � Click the “Restart” button � Both buttons turn colours. The red button is for the warm start function, and the blue button is for the

cold start function.

� Select the required function by clicking the required button. MSP The send counter indicates whether the MSP is operating properly. During normal operation, the send counter changes by a specific amount (13) every 2 seconds. You can also release the device configuration. To do so, click the “Configuration” button. If the “Configuration button” is active, it flashes green. Click the button again once the configuration is finished. After 60 minutes, the system automatically ends configuration mode.


6.2. Fault alarm parameters

On this page, you can set the parameters for all fault alarms. There are two options for navigating through the parameters: � Using the forward and back arrow keys (each moves one alarm) � You can also enter the fault alarm number directly

There are two groups of fault alarms. One group monitors a digital signal for 0 and 1. The other group monitors an analog signal for a limit value. The type of activation for analog fault alarms, whether the fault alarm is active when the value exceeds the limit value (max signal) or falls short of the limit value (min signal), is set in the configuration. In the first case, the fault disappears once it falls below the limit value minus hysteresis. In the second case, the signal disappears once it exceeds the limit value plus hysteresis. A time delay can be specified between the time when a fault appears and a fault alarm is triggered for both fault alarm types. Response thresholds are also activated for an analog fault alarm (limit value & hysteresis). Response to the fault occurrence can also fail for different reasons. Emergency stop Similar to pressing the emergency button, the module is stopped

immediately. All drives are deactivated. To restart the module, you must acknowledge the emergency stop using the reset button on the control cabinet.

Immediate stop The module is stopped immediately. The generator switch is opened without delay.

Controlled stop The module is unloaded. The power is lowered by a setpoint gradient. The module is stopped.

Alarm Only an alarm message is signalled. The module continues to run. Additional options: � Once the fault stops, it can be automatically acknowledged. Otherwise, it remains entered with the

current fault alarms until it is manually acknowledged. � You can also entirely deactivate each individual fault alarm. � You can also configure each fault alarm so that it switches on a collective fault relay.

Once the fault alarm is configured, you must also click the “Update parameter” button. The new parameters are then active. The button turns green.


6.3. Parameters

On this page, you can set the parameters for all module parameters. There are two options for navigating through the parameters: � Using the forward and back arrow keys (each moves by one number) � You can also enter the parameter number directly

The name, unit and limit values are displayed for each parameter. Once the parameter is configured, you must also click the “Update parameter” button. The new parameters are then active. The button remains green for 3 seconds.


6.4. Analog parameters

On this page, you can set the parameters for all analog values. There are two options for navigating through the analog values: � Using the forward and back arrow keys (each moves by one number) � You can also enter the number directly

If this page is active, all fault alarms that refer to this analog value are suppressed. This allows you to adjust sensors without fault alarms constantly appearing. Once you exit the page, the fault alarms are active again.

You can also simulate (force) each analog value. To do so, enter the force value and activate the force procedure. The value is evaluated in the entire program. An additional fault alarm appears indicating that a value is forced. This makes you aware of the force function.

Signal form: Determines the type of measured value scale according to the following diagram: Value: Signal form: Input min. Input max. 1 Input 0 – 20mA 2 Input 4 – 20mA 3 Input 0 – 10V 4 Input PT 100 -2000 8500 5 Input thermoelement type K -27000 13720 6 Output 4 - 20mA 7 Output 0 - 20mA 8 Output 0 - 10V 9 Input PT 1000 -2000 8500

Offset: Use offset to compensate deviations in the measuring signal which result from different line lengths (e.g. PT100). Decimal point: Number of decimal places in the measured value. Once the analog value is configured, you must also click the “Update parameter” button. The new parameters are then active. The button turns green.


Switching from PT100 / PT1000: In order to configure a channel from PT100 to PT1000, the following procedure must be selected: - Set standard (PT100 = 4, PT1000 =9) - Click the "Update parameter" button - Warm-start the CP3485 (switch off the CP3485 briefly via the system overview or 24VDC power supply). Attention: The machine must come to a standstill!

6.5. Options parameters

Use this page to configure the entire system. All optional functions can be activated or deactivated. Only with the corresponding access level it is possible to change an option. Grey cells could not be changed with the actual access level. With a click in the cell of the column parameterizing you can set or reset an option. With the button “write parameter” you send the new configuration to the PLC. The PLC is checking the new configuration to their plausibility. If there was a change to not valid combination the PLC resets the wrong options.

You can only select those options that are also made in the hardware. Otherwise, the CPU can run in stop mode (e.g. if a profibus module is not present but was activated in the options list).


6.6. Emergency cooler parameters

On this page, you can set the parameters for all emergency cooler parameters. There are two options for navigating through the parameters: � Using the forward and back arrow keys (each moves by one number) � You can also enter the parameter number directly



6.7. Room fan parameter

On this page, you can set the parameters for all room fan parameters. There are two options for navigating through the parameters: � Using the forward and back arrow keys (each moves by one number) � You can also enter the parameter number directly



6.8. Heat operation parameter

On this page, you can set the parameters for all heat operation parameters. There are two options for navigating through the parameters: � Using the forward and back arrow keys (each moves by one number) � You can also enter the parameter number directly



6.9. Test Facility

Use the Startup button to start or stop the startup program. (Key switch must be on “Release module”, “Local control” and “Automatic”.) The 4 power levels of the startup program are displayed in the upper left side of the screen. The current level, i.e. at which position the startup program is, is displayed on the top right side of the screen. The lower part of the screen indicates whether the startup program has been run properly (the corresponding LED turns green). If a stop interrupts the startup program during one of the phases, the time and levels already expired are stored. Once the fault has been remedied, the program continues at the stored startup mode position. Logging Click the “Logging” button to release the measuring data transmission to the MDE test stand. To do so, plug a serial cable into the RS232 and connect a TTY converter between the two. Once the log is completed, you must click the button again. Otherwise the interface remains occupied. Attention: If an additional interface (RS232) in the project is active, this communication must be deactivated while logging.


6.10. M-Graph: Single channel See description chapter 5.43

6.11. M-Graph: Single channel intraday See description chapter 5.42

6.12. M-Graph: System See description chapter 5.44

6.13. M-Graph: System intrady

You can graphically display eight import measuring values using this online recorder. All values are updated every minute. Selecting channels: The channels can be faded out or in by pressing their button.

Press button to see with value is aligent to which y-axis and with which scale. Press the button again to close this help. Display range of the time axis (X): The time axis is always 24 hours. It is possible to go back for 30 days. Scaling the measuring ranges (Y): The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using two parameters. You can improve the visual resolution in the desired measuring range using these parameters. Activating: The channels are automatically saved in the database (time period over 30 days).


6.14. M-Graph: Heating Water

You can graphically display all important values of the heating water controller using this online recorder. A maximum of 8 channels are displayed. The controller reads all values in one second cycles. Switching on/off channels: The channels can be displayed/or hidden by pressing the corresponding buttons. Display range of the time axis (X): The time axis can be set to 4 display ranges (1 / 5 / 10 /15 min). The active range is highlighted in green. Scaling the measuring ranges (Y): Two Y-axes are available: The actual values are scaled in % on the left side. The actual values are scaled in °C on the right side. You can change both axes using two parameters. You can improve the visual resolution in the desired measuring range using these parameters. Activating: Click “M-Graph on” to activate the M-Graph. Click the button again to end the function.


7. Hardware descriptions

7.1. IPC

7.1.1. Possible fault causes

� No power supply => measure the voltage at the plug. � Incorrect power supply polarity => check the plug � External keyboard and mouse (optional pluggable) may be incorrectly connected. � Defective memory => generally a message appears when you start the computer � PC starts but the screen is blank => touchscreen may be defective � Accessories (e.g. ISDN card) are incorrectly connected or defective � PC starts but no connection to the control can be established => check node number on the

IF681, test the Ethernet wiring, check the network card, check project settings if necessary.

7.1.2. Establish remote access (e.g. customer)

See separate description "Setting up remote access for customers V6"

7.2. Interface modules for control

See separate description


7.3. CP3485

In progress!!!


7.4. MSP

Adjusting or checking CAN connection to PLC:

� Screw the CAN connector on CP3485 onto the left hand “CAN” interface. � Check node number on PLC. � Connect CAN lead to MSP and set the correct CAN-ID (set via MSP Display).

During transmission of operating system for PLC Baud rate must be set to 125 kbit/s. Control may

function at 500 kbit/s, but “MSP” cannot function with more than 125 kbit/s. Set MSP parameters on display:

“Select” “Numeric” “Position”

� Switch power on. � Input “34” on MSP must set to a 24V signal and input “33” to 0V. � Selecting input mode: Press “numeric” and “position” together at same time => input mode will start

and the “Test” LED flash. The system is now in parameterising mode. If you wish to exit this mode at any time, press down “Numeric” and “Position” again simultaneously.

� When in parameterising mode, pressing the “Select” key will move you through the various parameters (forwards only).

� When desired parameter has been found, setting can be adjusted by pressing “Numeric” button. For parameters of more than one position, set the cursor to the right position by pressing the “Position” key. Pressing the select button, confirms the parameter setting.

� To exit parameterising mode, press “Numeric” and “Position” keys down again simultaneously.

Important Basic Settings: � Set “Direct parameterising” to “Off”. � Set “Generator Number” to “1” � Set “Base ID” to “0600” � Set “Parameterising ID” to “0620” � Set “Control via interface” to “On”

Parameterising via LeoPC

See separate description "LEOPC"!


7.5. LAP 2440-3 Battery charging device Output voltage is set using a potentiometer. This is located on right next to the output terminals (underneath device).

Documents

MMC-4000 manual