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TOTAL CONTROL SYSTEM

CHP controller

Users manual

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Foreword

This manual is written for the user of the Total Control System, TCS. This book is an
explanation of the hardware and software of the system. The Group ‘LEKHABO’ has got the
right to make changes in hard- and software and will try to describe those changes in future
descriptions. The TCS-user has to check the compatibility of software and manual version.
The manual version number is placed at the bottom of the page and is formed out of
software version and publication character. The version number describes also a date of
publication.

The reader can not extract any rights out of this publication according to damages due to
impropriate use of the installation.

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Summary

1 FUNCTIONALITY ................................................................................ 5
2 SYSTEM HARDWARE .......................................................................... 6
2.1 CCPU ........................................................................................... 6
2.1.1 Power ..................................................................................... 7
2.1.2 CCPU operation states............................................................... 8
2.2 MODULES ....................................................................................... 8
2.2.1 CBM ....................................................................................... 9
2.2.2 CVIP ..................................................................................... 10
2.2.3 CIO ...................................................................................... 11
2.2.4 COI ...................................................................................... 12
2.2.5 CTH ...................................................................................... 13
2.3 COMMUNICATION ............................................................................ 13
2.3.1 CANbus................................................................................. 13
2.3.2 Ethernet................................................................................ 14
3 CONTROL AND VISUALISATION ....................................................... 16
3.1 CONTROL ...................................................................................... 16
3.1.1 Touch screen ......................................................................... 16
3.1.2 Engine key ............................................................................ 16
3.1.3 Reset button .......................................................................... 17
3.1.4 I-Button ................................................................................ 17
3.2 STRUCTURE DISPLAY ........................................................................ 18
3.3 MAIN MENU ................................................................................... 18
3.4 WINDOWS .................................................................................... 19
3.4.1 Overview............................................................................... 19
3.4.1.1 CHP common screen ................................................................................19
3.4.1.2 Counters ....................................................................................................21
3.4.1.3 Thermal .....................................................................................................22
3.4.1.4 Thermal overview ......................................................................................22
3.4.1.5 Mechanical ................................................................................................23
3.4.1.6 Electrical ....................................................................................................23
3.4.1.7 Light control ...............................................................................................24
3.4.1.8 Co2 ............................................................................................................26
3.4.2 Module overview .................................................................... 26
3.4.2.1 Module.......................................................................................................27
3.4.2.2 Module connector ......................................................................................28
3.4.2.3 Screen digital I/O element .........................................................................29
3.4.2.4 Screen analogue I/O element....................................................................31
3.4.3 Project info ............................................................................ 32
3.4.4 Error list................................................................................ 33
3.4.5 Parameters............................................................................ 33
3.4.5.1 I/O points ...................................................................................................34
3.4.5.2 Parameters ................................................................................................34
3.4.5.3 Clock adjustment .......................................................................................35
3.4.5.4 External Login............................................................................................36
3.4.6 Regulations ........................................................................... 36
3.4.6.1 Thermal .....................................................................................................37

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3.4.6.2 Electrical ....................................................................................................37

3.4.6.3 Mechanical ................................................................................................39
3.4.6.4 Engine state...............................................................................................39
3.4.6.5 Power regulation........................................................................................39
3.4.6.6 CO2 ............................................................................................................40
3.4.7 System info ........................................................................... 40
3.4.8 Graph ................................................................................... 41
4 ERRORS AND MESSAGES .................................................................. 43
4.1 INSTALLATION ERRORS ...................................................................... 43
4.1.1 Digital errors ......................................................................... 43
4.1.2 Analogue errors...................................................................... 43
4.1.3 Electrical errors ...................................................................... 44
4.1.4 Thermal errors ....................................................................... 44
4.1.5 Mechanical errors ................................................................... 45
4.1.6 Sensor error .......................................................................... 45
4.2 INSTALLATION MESSAGES................................................................... 45
4.3 SYSTEM ERRORS ............................................................................. 45
5 REGELINGEN.................................................................................... 46
5.1 CHP CONTROLLER ........................................................................... 46
5.2 ELECTRICAL ................................................................................... 46
5.2.1 Synchronization ..................................................................... 47
5.2.2 Voltage matching ................................................................... 47
5.2.3 Pfcontroller ............................................................................ 47
5.2.4 Power regulation .................................................................... 47
5.2.5 Import/export ........................................................................ 47
5.2.6 External power demand........................................................... 48
5.2.7 Loadsharing........................................................................... 48
5.2.8 Lighting ................................................................................ 48
5.3 THERMAL ...................................................................................... 48
5.3.1 De-rating .............................................................................. 48
5.3.2 High temperature control......................................................... 49
5.3.3 Cascade temperature control.................................................... 49
5.3.4 Cascade mixture .................................................................... 49
5.3.5 Emergency cooling.................................................................. 49
5.4 MECHANICAL ................................................................................. 50
5.4.1 Waterpressure ....................................................................... 50
5.4.2 Oil make-up........................................................................... 50
5.4.3 Speedcontroller ...................................................................... 51
5.4.4 Air/fuel ratio .......................................................................... 51
5.5 CO2 ............................................................................................ 52
5.6 BIOGAS / DUAL FUEL ........................................................................ 52
INDEX ................................................................................................... 53

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1 Functionality
Total Control System, TCS, is build out of different modules and a central microprocessor
control unit with touch screen display. The connection between modules and central control
unit is based on CANBUS.
A modular system make it possible to make a project- installation specified configuration.
Use of a specified number of input and output elements ( digital and analogue ) make that
the change of shortage or balance is limited.

Due to the modular construction with the use of canbus, the control unit can be placed on a
chosen location. On the application of the CHP, the control unit with touch screen is placed in
the door of the CHP controller switchboard while sensors and contacts on the CHP are
connected close to the engine in a small box.

Next functions are specified in the software for the CHP in the control unit :
Protection:
o temperatures trough Pt100 sensors thermocouples and thermal contacts ;
o Pressure trough pressure sensors and pressure contacts etc;
o Electrical values Current, voltage , power and cos ϕ;
o Rotation trough magnetic sensor
Regulation and control
o Start and stop of the installation, start engine , speed regulator , gas valves and
ignition are controlled by module in the engine box;
o Controlling auxiliary tools, ventilator pumps and heating etc.
o Synchronisation and power regulation. When mains-parallel configuration is
used, synchronisation through controlling rotation speed in function of voltage
angle between mains and generator, coupling engine to the mains , desired
power regulation;
o Voltage matching and power factor control: While the unit synchronises to the
mains, the voltage of generator is regulated to the mains voltage by regulation
of the base voltage of the generator’s voltage regulator. The same signal is
used to regulate the engine to a desired cos ϕ while running parallel to the
mains.
o Temperature regulation with 3 way valves;
o Engine water pressure regulation by open expansion tank and pump;
o Oil supply regulation.

More information according to protection and regulation can be found in chapters further on
in this manual

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2 System hardware
The different items of TCS are the central processor unit and different I/O modules.
The modules send collected information to the CPU and translates information from the CPU
to the outside.

2.1 CCPU
The central processor unit is developed with a CANBUS data bus technology system.
Therefore the name of this unit is Can Central Processor Unit, CCPU.
The CCPU is accompanied with a touch screen display and the total is designed as a
component for a front mounting, i.e. into a door in a switchboard.

Build 1, CCPU front and back

Onto the front of the CCPU

- touch screen 8 colour display;
- engine key;
- reset button;
- I-button, login, key.

At the back side of the CCPU:

- 3 times CANbus onto 5 pole phoenix connector;
- RS485 connector onto 4 pole phoenix connector (i.e. Modbus);
- buzzer;
- connection for key , buzzer and reset button onto 4 pole connector;
- connection i-button onto 4 pole connector;
- 8 pole phoenix connector with:
o 2 x digital output 24Vdc output;
o 2 x digital input , connect to 24Vdc;
o watchdog relays with no – nc contact
- RJ11 connection for analogue or ISDN telephone (modem internal);
- Connection optional DCF77 receiver (automatically time correction ).

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The left side is designed for several communication media.

- RS232 port;
- USB slave port;
- Smart media card reader (32, 64 and 128 MB);
- RJ45 Ethernet port.

build 1, CCPU left side

At the upper side of the CCPU is a screw to adjust the screen contrast. With a small screw
driver this screw can be accessed through a small hole in the protection cover.

In option, the CCPU could be equipped with a modem, analogue or ISDN. The telephone
line has to be connected in the RJ11 connector on the bottom of the CCPU

2.1.1 Power supply

The CCPU power supply is provided from a power unit in the switchboard and is coupled into
the CCPU on the Canbus connector. The power unit is a 24 Vdc stabilised power together
with a set of system batteries. The autonomy time of the power unit by interruption of mains
voltage is at least 5 hours. In case of emergency function, powering of the power unit is
taken over by the generator.

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The Canbus modules are powered through the canbus cable. De Voltages for the 3 Can
busses are isolated. When more than one Canbus is installed, different power connections
can be made.

The real time clock of the CCPU is continuously powered by a battery, connected onto the
CPU. It is a small battery from 3.2Vdc and has autonomy of 10 years.

2.1.2 CCPU operation states

The CCPU can be operated in different modes. The choice of these modes can be made by
a rotary switch at the left side of the CCPU. 16 different states can be selected ( 0 over F )
Next states are yet implemented.
1= auto start, test mode, only Ethernet and FTP server are started
2= auto start, normal operation mode
E= no auto start,
F= boot loader, another boot version can be loaded
Other positions ‘ll be implemented in the future

2.2 Modules

The modular design makes an installation depended configuration possible. At the same
time, changes in installation and extensional needs can be easily implemented. Extra
modules can be added afterwards. Also implementation of new developed modules is
possible. (due to the standardised protocol of CAN open – external modules could be placed)

At this time , 5 different modules are developed:

- CBM, Can basis module;
- CVIP, Can power module;
- CIO, Can Input/Output module;
- COI, Can Output/Input module;
- CTH, Can thermocouple module.

All modules are designed at the same platform, and all have common characteristics:

Housing; Aluminium housing on a Din-rail mounting

CANbus input-output; two 5 pole connectors are used to connect the module in bus
structure.

Address switch; rotary switch to choose Canbus address for that type of module. Each
type of module can only have one unique address at the same canbus. Switch can be
set from 0 to E( 15) . Position F is foreseen for boot loader programming.

Rs232 port; Sub-D 9 pole male connector for serial connection with the module

Rs485; 4 pole connector for a serial databus connection with the module

Led’s signalisation
- Power ON fix green when 24 Vdc is connected
- Activity slow red blinking when module is operational

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- Can OK Blinking when module synchronises to the CCPU, continuous

green when in normal operation.
- Can error Blinking orange when error is detected on the bus. In normal
conditions out.
- Rx RS232 blinks on receiving data
- Tx RS232 blinks on transmitting data
- Rx RS485 blinks on receiving data
- Tx RS485 blinks on transmitting data
- Trip ( upper side of module between the 2 16 pole connectors.
activates one time when the module becomes a reset
- 40 leds displaying information on i/o according to functionality of modules, the
leds have different signal states:
Digital IO element (CVIP/CIO/COI):
- out no element or i/o is not activated
- on digital i/o is activated
- fast blinking digital i/o is simulated on;
- slow blinking digital i/o is simulated off;.
Analogue IO elements (CBM/CVIP):
- out no element .
- on analogue i/o is configured
- fast blinking analogue i/o is simulated.

The i/o leds are direct controlled by the CCPU. This is only possible when Canbus is
fully operational. In all other cases the i/o leds are off

build 2, CAN module.

The description of the different modules will be explained module by module.

2.2.1 CBM

The abbreviation CBM stands for CAN BASE MODULE, also Can basis CHP module. The
module contains all analogue i/o for a small CHP ; measuring temperatures, pressures ,
controlling governor and generator exitation.

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build 3, CBM module

Contents of the CBM module

- 2x voltage output –10 / +10Vdc, galvanic isolated to 30Vdc;

- 3x current outputs 4-20mA, (0-20mA);
- 4x current inputs 4-20mA, (0-20mA);
- 1x Pwm output, 20kHz;
- rotation speed through magnetic sensor
- 2x voltage input –10 / +10Vdc;
- 6x Pt100 input;
- 3x thermocouple input type K;
- Potentional measurement input, standard for actuator feedback;
- Voltage input 30Vdc, standard for measurement starter battery voltage;
- Shunt input 60mV, to measure start battery load current
- Internal measurement of system battery voltage 30Vdc via CANbus.

2.2.2 CVIP

The abbreviation CVIP stands for CAN V- Voltage, I- Current, and P-Power measurement.
This module is developed to provide total power measurement on generator and mains.
On both sides (when current transformers are in place) total energy values can be measured.

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build 4, CVIP module

Contents of the CVIP module

- 8x voltage input 300Vac;
- 6x voltage input 5Vac, for current measurement over current transformers
xx/1A with an external resistor of 5 Ohm 10 VA
- 3x digital input, 24Vdc switching to ground;
- 5x digital relays output, 2 contacts NO NC, 3 contact NO with common
connector, relays contacts 8A 250Vac / 5A 24Vdc.

The measurements on the CVIP can be separated into measurements of generator and
measurements of mains. Those two parts are equal.
- 3 phase voltage;
- 3 phase current;
- 3 phase power W;
- 3 phase power factor;
- angle voltage current to calculate cosphi; neg. = lead, pos. = lag;
- frequency;
- phase rotation angle ;

one time
- Phase angle between generator and mains ( for synchronisation ).

2.2.3 CIO

The abbreviation CIO stands for Can Input Output. The module has got more digital inputs
over outputs.

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build 5, CIO module

contents of the CIO module
- 30 digital inputs, 24Vdc switching to ground;
- 8 relais output as a potentional free contact NO relais contact 8A 250Vac / 5A
24Vdc.

2.2.4 COI

The abbreviation COI stands for Can Output Input. The module has got more digital outputs
over inputs.

build 6, COI module

Contents of the CIO module

- 15 digital inputs, 24Vdc switching to ground;
- 16 relays output as a PFC NO relays contacts 8A 250Vac / 5A 24Vdc.

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2.2.5 CTH

The abbreviation CTH stands for Can Termocouple. The module has got thermocouple
inputs only and is developed for large engines to measure cylinder temperatures.

Afbeelding 7, CTH module

contents of the CTH module
- 24 thermocouple inputs type K (NiCr-Ni), 50-2000°C.

2.3 Communication

The basic issue in TCS is communication. Between TCS and the different modules, between
TCS and other control equipment, between different TCS control units on one hand and
between TCS and the outside on the other. Therefore we have serial communication in
RS232 and RS485. Communication over gateway to profibus-dp. Communication over Can-
bus towards the different modules and communication over Ethernet, using different types of
protocols

2.3.1 CANbus

The information between different IO modules and the CCPU is transported using Canbus
technology. This technology is characterized by transporting lots of different data on a high
speed without any loss of data. The protocol which is used is called Can-open, a
standardised protocol.

The canbus technology, descriped in the international standard ISO 11898, is developed in
the automotive industry. With main raison to decrease the amount of cable, many different
cables and wires are replaced by one simple 4-wire cable. ( 2* power 2* data )

For our TCS application, a similar goal is realised. Sensors and protections on the engine
are centralised in a box on the engine itself. The information collected in the modules is

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transported over the 4wire cable towards the CCPU. So cabling of an installation is much
simplified.
TCS contains 3 identical Can Busses which makes a safe integration of different installation
parts possible. For instance one Canbus can be used for the CHP, another Canbus can be
used to control the lightning in a greenhouse (distance of this bus may be more than 300 m
which drops the speed of the information on that bus). Another canbus can be configured to
control a heating circuit.
The 3 canbusses could be configured on a different speed, according to the length of the
bus. In the table below you‘ll find the speed witch should be chosen to the length. At the end
of the bus , a resistor has to close the data communication wires , to avoid reflections on the
data wires.
Tabel 1, CANbus snelheid
speed [kbps] length [m] resistor R [Ω]
1000 < 24 120
500 24 - 160 120
100 160-360 150-300
50 360-1000 150-300

Next picture gives an example for the can bus structure

build 2, CANbus connection modules

2.3.2 Ethernet

Where Canbus is the connection internal in the TCS, Ethernet is the application to external
communication. This could be another TCS or a local area network ( LAN ) or WAN. The
Ethernet communication in TCS is accordance to standard IEEE 802.3.

The Ethernet connection between more than one TCS controller is adequate when

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- More than one CHP running parallel in an island situation - load sharing
master-slave situation’s, example : external building regulation
- More than one CHP uses same equipment

A connection with LAN or WAN makes a control (like on the touch screen possible in case a
fix IP address is involved

A network connection is made by Ethernet hub or switch witch is placed in the TCS
switchbox. Each participant on the bus got an unique no-network IP address or becomes a
IP address from a DHCP server when connected to this server

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3 Control and visualisation

The engine can be fully controlled from the touch screen in the switch panel door. In the next
chapter we ‘ll explain how to use the touch screen and where to find relevant information on
the screen.

3.1 Control

To control the unit , we have some services.

- a touch screen,
- a key switch
- a reset button, to make a reset on alarm / pre alarm
- an i-button reader ( writer ) , in different levels
The functions of these services are explained separately

3.1.1 Touch screen

On the display we have several types of objects
- Text with the text information is given, language can be
chosen
- Drawings graphical drawings from type BMP ( bitmap ) format 8
colours 16 bit . These drawings are stored on the file
system on the CCPU. Those drawings are displayed at
the screen.
- Buttons Different functions as programmed behind the buttons.
Buttons can be recognized as rectangles with rounded
edges;
- Combo box a combo box is a rectangle with textual information. By
selecting the box, a window with other possible choices
is drawn. Selection of another possibility by pushing
that part of the combo box;
- Number box a number box, to be recognized as a rectangle can be
pushed to change a value; depending of the level of
login ( see further in this manual) a value between min
and max or any number can be entered. ( min and max
value is draw at the bottom level of the display;
- Numeric keyboard Is put on the screen to change the value of a number
box.
- Textbox a text box, to be recognized as a rectangle can be
pushed to change a name. Used for the external login
- Alfa- Numeric keyboard is put on the screen when selection of a text box.
“QWERTY” keyboard.

Those elements will be explained further in the manual, together with the drawings and
description of the different screens.

3.1.2 Engine key

The engine key can be seen as switch to start and stop the installation. By putting the key to
1, the installation is ready to start in according to the chosen state; in most cases an external
start is needed to start the engine. By putting the key to zero, the engine will stop, possibly

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by reducing the load, when the engine is parallel to the mains, decoupling from the mains
and cooling the engine at zero load. By putting the key to zero, different regulations and
controls will be out of operation, like oil supply regulation.

3.1.3 Reset button

The reset button services the cancel of the fault status and messages which appear on the
screen. Pushing the reset button will only be seen as a cancel of the error when the engine
has stopped and the engine key is put to zero. When the controller detects a prealarm and
generates a message, this message and with this the pre-alarm buzzer, can be cancelled
with the engine running and key on 1. Every time the reset button is pushed, a message
RESET ENGINE is generated and put into the history/error list; When pushing the reset
button and the error is still actual; a new message is generated.

3.1.4 I-Button

The i-button is a programmable electronic key. This key is necessary to make adjustments
in the engine software and is needed to protect the engine against changing parameters
without permission. This key can be programmed with several entry levels. These levels
authorise to change parameters between or outside certain limits.
While pushing the i-button onto the reader, an acceptation sound is created and at the top of
the display the initials, name and level, as well as the minutes left are written to the screen.
Also a green led inside the I-button reader is lighted. The session stops when the time has
run out or when the user pushes the small button at the left upper corner of the display.
The login can be done also on the touch screen. By selecting PARAMETERS – EXTERNAL
LOGIN, a name and secret code can be generated and will have the same function as the I-
button

Changing of parameters can be done when the login level is correct –depending on the
parameter. Also the level gives the user the permission to change the parameter between
limits or outside these values. The final acceptance by the controller is done after an
UPDATE button is pushed; again this update is depending on the entry level to be accepted.
The present entry levels are displayed in next table.
Tabel 2, Access level acknowledgement
level Action possible Persons Label

no Visualisation all -
0 Same as before client black
Clock definition
Changing system time ( summer winter time )
Changing parameters level 0 between limits
1 Same as before Service mechanic blue
Reset service- and counters
Changing parameters level 1 between limits
2 Same as before Commissioning red
Simulation io-elements engineer
Changing values io-elements
Changing parameters level 2 inside limits
5 Same as before Software engineer green
All changes outside defined limits
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3.2 Display structure

The use of a touch screen makes it possible to use a logical structure between different
screens of information. Different menu and sub-menu’s can put into different layers makes it
easy to enter the information required.
A mix of information in graphical screens, where numeric information is aided by graphical
design as well as display with information in purely text. Next drawing gives an overview of
how information can be selected. Further in the manual those different screens are
explained.

build 3, screen structure

3.3 Main menu

At the left upper corner, a blue rectangle displays the actual menu on the screen.
By pressing this button, a menu appears. Next items can be chosen:
o overview main screens with measurements in graphical screens;
o module overview overview of all modules connected to the can buses;
o project info information about the project;
o history list of history ; messages and errors;
o parameters to control parameters / time clock;
o regulations status off all present regulations and controls;
o system info system state and connection data;
o graph history in graph format.

The installation operation is done by a selection button, at the left under corner of the screen
o service running engine at zero power
o Hand running engine by controlling parameters on the screen;
o Auto running engine in automatic state;
o Emergency running engine in emergency operation ( if present).

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A description of the operation can be found in the chapter regulation, CPH operation.

Build 8, Menu pulldown

3.4 Windows

All windows and sub (sub) windows will be explained separately.

3.4.1 Overview

Different options in the overview window:

- Common electrical state of engine with some important data
- Counters counters of different kinds
- Electrical overview of al electrical parameters of CVIP module+ graphic
display of voltage , current and power of generator
- Thermal list of thermal measurements
- Therm.graph. flow diagram of water with measurement points
- Mechanical mechanical values of installation analogue and digital
- Lighting with light controlling operation , overview of currently operated
light blocks
- Co2 principal overview of exhaust gas values

3.4.1.1 CHP common screen

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build 9, screen overview CHP common

This principal screen gives a simplified overview of the engine state:

- Power , current, frequency, of the generator;
- Engine rotation speed , oil pressure and engine water temperature;
- Message accompanied with an icon:

Engine running , no further action necessary;

Message present , attention required;

Engine in error state ; action required;

Service nearly reached ;

engine stand-by, wait for external start;

key on zero , engine stopped ;

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engine disabled by time clock;

Engine starting or stopping.

Besides this numeric information , a drawing of a CHP is given and an electrical one-wire
picture is drawn that ‘ll be related to the project installation. Different possibilities are :
- Island operation
- Parallel operation with or without mains coupler
- Combination of the above

On installations, designed with more than one CHP or with very complex electrical
construction, a separate screen can be chosen

3.4.1.2 Counters

build 10, Screen counters

Possible counters are :

- Total engine hours counter;
- Service hour counter;
- Engine running at zero load;
- start attempts;
- kWh electrical;

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- kWh thermal;
- gas consumption;
- oil consumption;
- hours light ( greenhouses);
- hours CO2 delivery.

The service counter can be reset ( over login button ) A reset button appears when the
operator has a level which is high enough to reset service hours.

3.4.1.3 Thermal

build 11, screen thermal

A list of possible thermal values. When the measurement is not used , only text will be
displayed without a value.

3.4.1.4 Thermal overview

The thermal overview makes practical drawing of the water flow in the CHP installation.
A possible flow schema is draw in next build

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build 12, thermal principle

3.4.1.5 Mechanical

build 13, Screen mechanical

Same as on the thermal screen, only present measurement points are displayed.

3.4.1.6 Electrical
This screen gives information on average phase voltage , current and total power of the
engine. Further all values of energy coming from CVIP module are displayed. On generator
and mains we‘ll find following values:
Pro phase: voltage, current , power , cosphi , phase difference to phase 1 frequency and
total power factor.
The phase difference between phase 1 of generator and mains is also displayed.
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Afbeelding 14, Screen electrical

3.4.1.7 Lighting control

This screen is only present when a light controlling operation is required. The screen
displays an overview of all present light boxes
Every box can have another color according tot the state
- Yellow : active
- White : Off
- Red : Off and in cool period ( no activation possible )

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build 15, Screen overview light control

All buttons of light can be selected by pushing; next screen will appear :

build 16, screen control light controller

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In this screen, every group of light can be put on/off by hand or put on automatic selection.
The state and possible cool period‘ll also be displayed

3.4.1.8 Co2

This screen can only be selected when a exhaust gas cleaner is connected to the controller.
It displays the exhaust piping of the installation with CHP, the exhaust gas cleaner and the
different valves and regulation valves. Also the relevant data , in the next drawing an
example of exhaust gas cleaner in combination with 1 CHP installation is displayed.

build 17, Screen CO2

The regulation can be put on/off with a button ( selection box ) at the bottom of this screen.

3.4.2 Module overview

All modules, connected to the can bus are displayed

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build 18, Screen module overview

On a standard CHP, the next modules are connected:

In the CHP control panel:
CVIP: voltage, current measurement. On generator side and mains side
COI: external contacts to the costumer, ….
In the Motor switch board on the engine:
CBM: speed , temperature , pressure
CIO: protection gas pressure, switches, commands to start engine, gasvalves ….

When selecting a module , this module ‘ll appear on the screen ( 3.4.2.1 )

3.4.2.1 Module

In this screen , the module is shown with all connected io elements:

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build 19, Screen module

The color of a button ( io element ) displays the state of a i/o element: possible error state or
simulated. Green mains no error detected , red mains error detected, yellow means i/o
element is simulated.

Two buttons at the left upper screen referring to:

1. Info module, information on the module is displayed:
- module node ID, module type and CANadres
- the module name
- the serial number ( also written at the bottom of the module itself)
- the hardware version
- the software version

2. calculated i/o points. In case of an analogue module, useful information can be

calculated with different io-points. On the CVIP module, a number of calculated
iopoints is generated, frequency ( out of voltage measurement) , cos phi and power
out of calculation from voltage and current. Selection of these points will result in a
similar screen as physically connected io-points, see further on the screen analogue io
element .

By selecting any of the io-elements on the screen, an selection of the io-elements at 1

connector is displayed. Module connector screen‘ll be displayed.

3.4.2.2 Module connector

In the screen module connector, the terminal numbers with connected io elements are
enlarged. Behind the name of every element the state is displayed in a box. i.e. for digital
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elements on box ON/OFF or in case of analogue element the actual value. These values and
states are real time.

build 20, Sceen module connector

by selecting the text box ( io element ) , all characteristics of this element are displayed. Two
different screens could be displayed according to digital or analogue io element

3.4.2.3 Screen digital I/O element

On the screen , information about name, place and module, i/o element real time status, as
well as setted protection states and characteristics in case of inputs is displayed.

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build 21, Screen digital I/O element

the state of the digital io element can be separated into

- Hardware value
- Software value
- Simulated value

A desired simulated value of a digital io element can be selected by selecting the check box ,
an input or output high Æ checked
An input or output low Æ not checked
Also the simulation enable has to be checked to actual simulate that io element.
Final acceptance is done by pushing update button. From that moment io element ‘ll be
simulated. Login at certain level is required

Relation between simulate value , hard and software value is different for input and output:
Next relation can be found:

Digital outputs:

Hardware value is done by controller, out of a choice between software value or simulate
value, depending on the state of simulate enable. On simulate enable, the hardware value
equals the simulate value. On simulate disable, the hardware value equals the software
value.

Digital inputs:

Software value is done by controller, out of a choice between hardware value or simulate
value, depending on the state of simulate enable. On simulate enable, the software value

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equals the simulate value. On simulate disable, the software value equals the hardware
value.

When a digital input is in use as a protection , this can be configured on the screen ( or
changed from original software ). Two changes of state can be programmed with related
conditions and handling:
- Enable : checked : protection available
- Value: in this state ; the protection ‘ll generate an error/message when condition is
true;
- Delay: time delay before error/message will be detected
- Condition: engine condition state; only when this state is true , the error/message ‘ll
become activated ( after delay period );
- Handling: when error/message is detected ; the engine has to react in certain
procedure, this could be a stop af the engine or generation of a message.

The change of protection parameters is only possible when the user has a sufficient level of
control. ( see chapter of i-button ). When no user is logged in to the system; those
parameters can be visualized but not changed.
Every change of parameters is written into a log-script with time initials.

3.4.2.4 Screen analogue I/O element

This screen is similar to the digital i/o elements but instead of 2 protections we’ve got 4
possible protection trigger values: 2 times under level , 2 times upper level.

Build 22, Screen analogue IO element

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For the analogue inputs 2 more parameters are added to convert sensor signals into
measured values. Offset is the value witch is added to the hardware value, Gain is a
parameter to multiply this to get the measured value. With this every input can be fit into a
range of a specified sensor.

Example : oil pressure sensor :

Sensor: 4-20mA = 0-10bar
Offset: -4mA
Gain: 10-0bar/20-4mA = 10bar/16mA = 0,625bar/mA

Simulation of measured value is similar to digital input/outputs,

Simulate enable will make the simulate value become active.
Simulate value is a number box in witch the value can be programmed. The update button ‘ll
activate the possible simulation. ( under condition of login entry level. )

Relation between simulate value , hard and software value is different for input and output:
Next relation can be found:

Analogue outputs:

Hardware value is done by controller , out of a choice between software value or simulate
value, depending on the state of simulate enable. On simulate enable, the hardware value
equals the simulate value. On simulate disable, the hardware value equals the software
value.

Analogue inputs:

Software value is done by controller , out of a choice between hardware value or simulate
value, depending on the state of simulate enable. On simulate enable, the software value
equals the simulate value. On simulate disable, the software value equals the hardware
value.

When an analogue input is use as a protection , this can be configured on the screen ( or
changed from original software ). Two trigger values under level and two trigger values upper
level can be programmed with related conditions and handling:
- Enable : checked : protection available
- Value: exceed or lower value ; the protection ‘ll generate an error/message when
condition is true;
- Delay: time delay before error/message will be detected
- Condition: engine condition state; only when this state is true , the error/message ‘ll
become activated ( after delay period );
- Handling: when error/message is detected ; the engine has to react in certain
procedure, this could be a stop of the engine or generation of a message.

The change of protection parameters is only possible when the user has a sufficient level of
control. ( see chapter of i-button ). When no user is logged in to the system; those
parameters can be visualized but not changed.
Every change of parameters is written into a log-script with time initials.

3.4.3 Project info

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Under construction

3.4.4 Error list

build 23, Screen error list

In the screen, errors and messages are numbered. The number, date, time, error/message
description, value and error-mode are written for every error/message. Number 1 is placed
with the latest error/message occurred. Changing to previous or next errors results into
displaying next list of 20 errors/messages. The previous 500 errors/messages can be
displayed.

Messages ( pre-alerts or warnings ) and errors ( alerts or faults ) can be reset with reset-
button as explained in chapter concerning reset button. This screen is not updated, new
errors/messages are only displayed by entering the screen again.

3.4.5 Parameters

The screen parameters consist the next buttons

- I/O points, locations of hardware elements;
- Parameters, changing or visualizing parameters for regulation;
- Clock adjustment in time clock and visualization of time regulation;
- External login, login with code instead of i-button.

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3.4.5.1 I/O points

This screen is only selectable with highest entry level, this is not further explained in the
manual.

3.4.5.2 Parameters

Build 24, Screen parameters

In the parameter screen next items are displayed :
- Button to get information about parameter;
- 3 number boxes to enter required parameter;
- buttons to change parameter group and parameter item;
- The parameter group name ;
- The parameter name;
- The parameter value;
- The minimal entry level to change the parameter value.

The update button is only available when i-button is used.

The parameter number consists of 4 numbers ( like IP-adress )

In the parameter screen only 3 numbers has to be given. Parameter number is to be found
in parameter list accompanied with the engine or can be found in the information screen on
regulation window.

To change parameter value, the number box with actual value has to be pushed. A numeric
keyboard appears to enter new value.

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Build 25, enter parameter value

At the bottom of the screen, minimum and maximum value limit is displayed to make input
possible in between this range; ( only with level 5 , changing outside this range is possible )
Next to numeric keys , next buttons are present
< erase last numbers
<< erase total number
M insert maximum number
m insert minimum number
When correct number is inserted, OK button has to be pushed. The new value is taken over
in the parameter value; only when update button is selected, the new value is taken in
account into the regulation. ( for pid parameters ; initialization of the regulation has to be
carried out. )

3.4.5.3 Clock adjustment

The engine can be enabled/disabled with an internal time program. Four choices can be
made for every day of the week. The activation is only active when Time clock activation is
on. In the other case, time clock is disabled.
Next choices can be made:
0 continues off
1 continues on
2 1 clock cycles
3 2 clock cycles

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In the boxes behind the day , first the cycles has to selected. When number 2 or 3 is
selected; the time can be entered. In the value of time, format is ( HHMM ) and will result in (
HH:MM .

build 26, Screen clock

Actual state of the time clock is displayed next to state time clock

3.4.5.4 External Login

In this window , simulate login can be done like i-button.

Name ( initials ) and secret code have to be entered.

3.4.6 Regulations

This menu gives all information about regulation parameters. Next items are displayed:
- Regulation name
- state, regulation active on/off
- set point to be reached
- process value which will be regulated towards the set point,
- output signal to regulate towards the set point
when possible, a graphical bar is displayed to visualize the regulation. The range of this bar
is also displayed as well as the set point in the middle.

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Together with every regulation, a button is present to visualize the parameters. By selecting
these parameters a new value can be entered. PID parameters can be changed while
regulation is active, when the reinitialization button is pressed. This is only possible when
the user got a sufficient high login level.

To create a clear overview of all regulations, these are separeted into different screens.
Next screens can be selected :
- electrical
- thermal
- mechanical
- engine state
- CO2 regulation

A description of these regulation windows can be found in the next points in this chapter.

3.4.6.1 Thermal

In the screen, thermal valve regulation is displayed,

In the screen example a high temperature regulation and emergency cooler regulation are
shown.

build 27, Screen regulation thermal

3.4.6.2 Electrical
Electrical regulations are displayed:
- Synchronisation
- Power regulation / load control
- Power Factor Controller
- VM , Voltage matching
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Electrical regulations are visualized same as thermal regulation screen.

build 28, Screen electrical regulation

When the button parameters is selected a list of parameters is displayed.

build 29, Screen regulation parameters

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To change values of these parameters, the numberbox of this parameter can be pressed.
The parameter screen ‘ll be displayed, after selecting “ get info” the parameter value is
displayed and can be changed ( entry level login necessary )

3.4.6.3 Mechanical

Under construction.

3.4.6.4 Engine state

In this screen , information about start and stop procedure is displayed.

Also the engine state is visualized:

build 30, Screen engine state

Also in this screen the parameter button can be selected to display parameters concerning
the start/stop procedure

3.4.6.5 Power regulation

Different parameters can control set point power; an overview of activated regulations are
displayed into the next screen:

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build 31, screen power control

The power set point as well as the result of different regulations and results of requested
power are displayed. Electrical and thermal regulation results and external power regulation
is visualized. With thermal regulation thermal values are displayed. When a temperature is
whitin control limits or exceeds the maximum value, the value box colors red. Buttons to
enter parameter values are also displayed.

3.4.6.6 CO2

Option on exhaust gas cleaning .

Under this option we have two regulations:
- Controlling exhaust gas cleaner
- “CO2 on demand” controlling the exhaust gas cleaner by-pass

In those 2 regulations, the controlling of the exhaust gas cleaner can be in an external
steering. When the installation is foreseen with an exhaust gas cleaner by-pass , the
controlling ‘ll always be integrated into the steering of the CHP.

3.4.7 System info

System info gives information about connection parameters. The IP-adress ( ethernet ) ,
mail-server IP adress and some FTP parameters. The software version can be found on this
page too.

At the bottom of the screen, system time is given. When login is activated, this time can be
adjusted with + and – buttons.
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built 32, Screen system info

3.4.8 Graph

In this screen, data, stored onto disk can be drawn as a graph. At the same time, 2 analogue
graphs can be drawn. The data can be selected in a list. Every data is stored pro day, a
new day ‘ll overwrite the old data, every minute maximum 10 values can be stored. Every
day can be drawn in a time-period of several periods :
0:00 – 6:00
6:00- 12:00
12:00 – 18:00
18:00 – 24:00
0:00 – 24:00

The scale minimum and maximum can be selected free.

Next picture is an example of a graph:

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Afbeelding 33, Scherm grafieken.

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4 Errors and messages

Errors and messages of the installation can be visualized in the screens overview and
history.

Every message is one line with following information :

Number in list – data-time – message – value – messagedisciption ( message , to low , to
high , digital )

4.1 Installation errors

Errors on the engine could be generated according to sensors and protections connected to
the engine. Most of the errors/messages are generated by inputs when values are reached
under certain conditions. These conditions can be seen in overview modules and then
selection of a certain input For digital inputs 2 different error/message ( 2 ) can be selected .
For analogue error/message, 2 under values and 2 upper values can be selected.

Besides, a number of errors/messages are generated where more inputs or combinations

are valid. For example: different levels of a temperature according to the power actual given
by the generator; relations between different currents.

In most cases the description of the error/message should give sufficient information about
the error/message. To have a better view in installation protections, a number of
error/massages are specified below.

4.1.1 Digital errors

Digital errors are effects of changing state of digital I/O elements. It means that the state of
that input is equal to the error/state under a certain condition for a specified time.
Below , a number of protections are specified.
- Thermostat, switch on temperature ( i.e. oil temperature )
- Pressostat, switch on pressure ( i.e. water pressure )
- Level switch , switch on liquid or gas level ( i.e. oil level )
- Flowswitch, switch on liquid or air flow ( i.e. water flow )
- Protection relais, protection with digital feedback on current , voltage , frequency ,
etc.

All these protections can be mechanical or electrical .

4.1.2 Analogue errors

Equal to the digital errors, also analogue errors/messages can be described.

These are analogue input elements connected to analogue sensors or analogue inputs,
calculated out of analogue sensors.
Below, some possible measurable analogue signals are listed.
- Current;
- Voltage;
- Frequency ;

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- Power;
- Temperature;
- Pressure;
- Flow;
- Speed.

The sensors convert the signal into a standardized electrical signal that can be connected to
the module. With offset and gain the hardware value is calculated into a software value.
This value is number of comparison with the error level. ( upper or lower ). Standard signals
that can be connected to the modules are :
- Pt100;
- Thermocouple type K;
- 0-20mA / 4-20mA;
- -10/+10Vdc / 0-10Vdc;
- current transformers 1A secundair (5Ω connected over transformer);
- voltage 30Vdc;
- voltage 230Vac;
- magnetic speed pick-up.

To view and under conditions change the values has to be done into screen : overview
modules- selection of input.

4.1.3 Electrical errors

Under electrical error are included:

Protection for generator and mains ; this could cause a direct ( possible temporarilly )
decoupling from the mains or a normal stop of the engine. ( with power reduction )
Some examples:
- Generator voltage to high/ to low;
- Generator current to high;
- Overload protection
- Generatorfrequency to high/ to low
- Power to high/ to low
- Reverse power generator – generator becomes motor

Also protection of pumps and ventilator are so called electrical protections, even these
protection are related to mechanical items. An overload of this item ‘ll cause a higher
current. The thermal protection relais ‘ll protect that item onto his nominal current. Raise
above this nominal current ‘ll result into opening of electrical circuit and detecting on open
input on the digital input . This ‘ll cause a digital error message.

4.1.4 Thermal errors

Thermal error become active when temperature raise above certain level. This can be the
case in several water circuits in the installation
- Engine water circuit;
- Lubrication oil circuit;
- Cooling water circuit;
- Exhaust gas ;

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- Exhaust gas cooling water circuit;

- Air temperature in container, environment;
- Gasmixture temperature.

4.1.5 Mechanical errors

Mechanical items in the installation are protected like :
- Water pressure;
- Waterflow (engine-, cooling-, exhaustcooler);
- Speed;
- Oilpressure.

4.1.6 Sensor error

Most sensors and protection equipment in the installation are designed as fail-safe. This
means that a wire-cut or error inside the sensor ‘ll result in an error situation.

4.2 Installation messages

Besides protection , different messages are displayed for information.

- Service message to inform the client to organize a service task on the engine
- Oil supplatoin message , in order to deliver oil or to inform about high/low level
of oil in supplation tank
- Temperature warning.
- Messages on coupling / external start / …

Messages are in the first place information to the custumor. Messages ‘ll not stop the
engine, Messages could be a first warning to further errors. Therefore , messages has to be
interpreted according to the message as information / warning to future possible error.

4.3 System errors

System errors lead to improper functionality of the system.

The installation ‘ll shut down because a correct function ‘ll not be guaranteed.
Possible errors :
- Buserror ethernet, communication error between different CCPU;
- CANbus error, Communication error between CCPU and one or more Can-
modles
- Module error, communication error with one module;
- System battery voltage

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5 Regulations
A number of regulations which are already in the engine are described here.
Those regulations are to be activated according to the installation. The description is only
the regulation description and does not replace the regulation philosophy which is the
responsibility of the installation’s commissioning engineer.

5.1 CHP controller

The CHP can be run in 4 modi:

- SERVICE Engine ‘ll run without coupling to the grid
- HAND Several regulations can be set active/ deactivate
- AUTO Automatically start/stop
- EMERGENCY Manual emergency operation ( if present )

In all these operation modi, the state of the engine is visualized in the screen engine state
Following numbers can be detected

mode 0: engine stand-by or is ready to start

Start sequence:
0 = prelubrication / pumps and ventilator
5, 6, 7 = control gasvalve ( when this control is active )
10 = startengine on
20 = ignition on
30 = gasvalve opens
40 = engine started : over to mode 15
41 = engine not started ; after 10 seconds new startattempt
mode 2: error
mode 15: running idle ( ramping to 1500 rpm )
mode 18: Synchronisation/ voltage maching to parallel operation or emergency run
Mode 30: emergency /island operation
Light – loadsteps regulation
Mode 35: parallel operation
Regulation on power ;thermal regulations , electrical regulations; external
regulations
Pfcontroller
Mode 34: Parallel-island operation
Loadsharing
KVAr regulation
Mode 50: Stop sequence:
0 = power reduction
1 = decoupling
2 = cooling engine
3 = stop engine
4 = stop direct

5.2 Electrical

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5.2.1 Synchronisation

Synchronisation is the regulation which tries to equalize the voltage phase angle of generator
and mains on phase control. Together with voltage matching we try to reach as close as
possible an identical voltage signal towards the mains or grid. Coupling the generator to the
mains is at this point the safest because only small currents‘ll be exchanged. The
synchronisation PID input is both frequency and phase difference (phase angle) between
generator and mains. The output is a signal to the speed controller to raise or lower the
speed of the generator.
When the phase angle stays for a defined time between a defined window, the generator
switch is closed. (installation dependent extra rules for closing could be installed )

5.2.2 Voltage matching

Voltage matching equalizes the voltage of generator and mains on voltage level. For the
same raison as synchronisation, this equalizes the voltage so coupling can be done if the
voltage difference of generator and mains is between a certain defined window.
This regulation is important because the voltage of mains can vary because of power
demands in the mains network.

5.2.3 Pfcontroller

The Power Factor Controller, also known as cos φ regulation is important to control the KVAr
in a generator. The regulation will vary the excitation of the generator towards reaching the
setpoint powerfactor demanded.
This value is set normally between 0.8 inductiv (lag) and 0.95 capacitif (lead). The amount of
KVAr in the installation is directed in according to the loads in the installation. The setpoint on
the generator can be used to compensate the demand of KVAr out of the mains.

5.2.4 Power regulation

Power regulation is used in mains parallel mode or for load sharing in island mode. On
calculation of desired and measured generator output, the engine fuel supply is being
increased or decreased.
Control is by means of a control signal from a CBM module the speed controller, which in
turn operates the gas engine’s governor and throttle.

5.2.5 Import/export

The electrical import/export regulation can be used on mains parallel machines when the
mains power is measured. The regulation setpoint can be an amount of power to be exported
as well to be imported from the mains. It is also possible to regulate on zero mains power,
the electrical consumption is totally covered be the generator power output.

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5.2.6 External power demand

The generated power can be set by an external device such as a Building mangement
System, by means of a external power demand signal. This option is valid for parallel mode
only. An 0-10Vdc or a 4-20mA signal can be used to make a desired power setpoint to the
machine. This setpoint can be used together with import/export and thermal power regulation
The least demanded power will be the setpoint for active power regulation.

5.2.7 Loadsharing

Loadsharing will be used on multiple generator island operation, several generators are
feedres a common isolated bus. The overall electrical consumption must be covered be the
connected generators. All generators must be equally loaded.

Each genset controller must be informed with a actual generated power figure from each
machine coupled to the bus. By summarise the different figures the machine can calculate its
own desired power. Power figures are communicated by means of ethernet.

Besides active power control on a shared bus, there is need to control reactive power, also
known as kVar sharing. This is commonly done by means of voltage droop in the generator
voltage regulator. Generator exitation is dictated by the amount of (reactive) current supplied
by the generator.

5.2.8 Lighting

Lighting control is used in greenhouses for assimilation lighting. When the genrator is ready
to load the lighting is switched on step by step. Time between steps can be set
independently for switching on and off. When a lighting step is switched off a cool down timer
is started to prevent the lights for re-starting.

A option is to make different lines of light, for instance 50% and 100%, these lines can be
operated independently according to the desired luminance level.

5.3 Thermal

5.3.1 De-rating

For de-rating power output in mains parallel operation, different functions can be
programmed. Three settings are needed to state the desired power for one measured
temperature. The next graph will clear this:

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Figuur 4, begrenzingslijn vermogen.

A de-rate line as stated above can be set for three different temperatures. Default are: jacket
water temperature (leaving), mixture temperature and supply water entering.

On island operation de-rating is possible by load-shedding. In case of lighting control, one or

more groups can be switched off.

5.3.2 High temperature control

High temperature control is a PID regulation to keep the engine at constant running
temperature. As teperature input entering as well as leaving temperature can be set.

5.3.3 Cascade temperature control

A cascade temperature control acts on a mixing valve in the supply water circuit by way of a
PID regulation. The setpoint of this PID is controlled by another PID which is a result of the
engine jacket water temperature. This means that in case of over-heating of the engine, the
mixing valve will be opened more and faster thus allowing more cooler supply water to the
engine. On the other side when the engine is on partial load the supply water temperature
can be increased in order to run the engine on normal, higest possible operating
temperature.

5.3.4 Cascade mixture

As cascade temperature control, but on mixture and intercooler entering temperature.

5.3.5 Emergency cooling

Regulations for emergency cooling are available in three different types made out of a dry-
cooler combined with a mixting valve or just a shut-off valve:
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- The mixing valve is controlling the machines entering suply water temperature, dry-
cooler fans are switched simultaneously;
- The mixing valve is controlling the machines entering suply water temperature, dry-
cooler fans are switched according to the mixing valve position;
- There is no mixting valve but a shut-off valve which opens on a temperature trigger,
the machines entering suplly water temperature is controlled by switching the dry-
cooler fans.

5.4 Mechanical

5.4.1 Waterpressure

To compensate volumetric dimensions due to temperature changes of jacketwater or coolant

inside the engine, the CHP is provided with an expension device. This device can be of three
different types:
- watertank with pressure cap;
- closed expansion barrel;
- open pressure tank with pump.

First two options are mechanical devices without need for regulation. The open pressure tank
however uses a pump to increase jacketwater pressure and a mechanical relief valve to
prevent over pressure. Switching of the pump is done by the controller on pressure settings
measured in the engine.

Older installations use a pressure switch for starting the pump with a minimum pumping time
of 30 seconds. The regulating pressure switch is mounted on the pressure tank having a
sensing pipe to the engine. Low pressure protection is by another pressure switch mounted
on the engine.

Later sets are equiped with an analogue pressure sensor. This pressure measurement is
used to make settings for starting and stopping the pressure pump with a hysteresis. The
same measurement is used to make a high and low pressure protection.

5.4.2 Oil make-up

In order to control the engine’s oil level automatically without usage of an oil daytank, oil is
suplied directly from the oil storage tank. The oil make-up pump is switched by two level
indicators, oil fill level and oil stop level, situated in a combined by-pass float-level indicator
mounted besides the engine. This indicator device also has two contacts for oil level
protection: oil level high and oil level low.

Oil pumping conditions:

- Machine key on 1
- input “oil fill level” active (oil has to be made up)
- input “oil stop level” not active (sump is allready filled)
- input “alarm level storage tank” active (oil storage tank is not empty)
- no oil level protection errors (too low or too high)

The oil make-up pump is stopped as soon as one of the following conditions is true:
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- input “oil stop level” active (sump is made up sufficiently)

- input “alarm level storage tank” not active (the oil storage tank is empty)
- oil level error (too low or too high level in sump)
- pumping time out (oil make-up timer ran out before reaching oil stop level)
- machine key on 0

When the oil make-up pump is started it can only run for a limitted. When the oil pump is
timed out the pump will be stopped and a message is given. Only by reseting this message
or by reaching the oil stop level the filling timer is resetted, thus when needed the oil make-
up can be re-commenced.

Besides an alarm level in the oil storage tank, which is in fact a run dry protection for the oil
make-up pump, there is as well an “order fresh oil” level which creates a message when
active.

With several engines using one storage tank only one set of floats is mounted, these will be
connected to the first CHP controller. The other controllers will receive status information by
means of the ethernet communication.

5.4.3 Speedcontroller

Under construction.

5.4.4 Air/fuel ratio

Under construction.

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5.5 CO2

CO2 regulations are described in a separated document: “Technical decription CO2 control”;
which contains desprictions of: Exhaustgas cleaner (catalist) with by-pass and CO2 on
demand.

5.6 Biogas / Dual fuel

CHP’s on bio gas are often fitted with double gas trains. The engine is capable to run on two
different fuels, i.e. natural gas and bio gas, ussual called “dual fuel”. The engine can run on
the clean and quality stable natural gas during start and cool down sequences while
delivering durable energy on bio gas. Starting and synchronising is normally better on natural
gas. After bio gas operation the engine can run clean on natural gas to ventilate and remove
the condensate and other toxic residues in the bio gas from the engine.

The CHP controller will, after synchronisation and coupling to the mains, switch over from
natural to bio gas. This event is done at a low power output in order to make a smooth
change-over and be in bio gas operation as soon as possible. After the change-over the
engine will ramp-up to desired power. At stopping the machine, the engine will be ramped
down while still running on bio gas, before decoupling from the mains will be switched to
natural gas. After decoupling the engine will idle for some time on natural gas.

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Index
Adress switch ...........................................8 i-Button ...................................................17
analogue I/O element .............................31 Led’s signalisation ....................................8
assimilation lighting ................................48 Loadsharing............................................48
Biogas ....................................................52 Machinesleutel .......................................16
CANbus ..................................................13 Module....................................................27
Canbus address ......... See Address switch Module connector...................................28
Cascade .................................................49 Module overview ....................................26
CBM .........................................................9 numeric keys ..........................................35
CCPU .......................................................6 Oil make-up ............................................50
CIO .........................................................11 operation modi........................................46
Clock adjustment....................................35 Pfcontroller .............................................47
COI .........................................................12 Power regulation ....................................47
Counters.................................................21 power supply ............................................7
CTH ........................................................13 process value ....................See regulations
CVIP .......................................................10 Regulations ............................................36
De-rating.................................................48 reinitialization button..........See regulations
Digital errors ...........................................43 Resetknop ..............................................17
digital I/O element ..................................29 rotary switch .............................................8
Display structure.....................................18 sensors...................................................44
Dual fuel .................................................52 setpoint..............................See regulations
Emergency cooling.................................49 Synchronisation......................................47
entry level ...............................................17 System errors .........................................45
Error list ..................................................33 Touchscreen...........................................16
Ethernet..................................................14 version number.........................................2
External power demand .........................48 Voltage matching....................................47
High temperature control........................49 Waterpressure ........................................50
i/o leds ......................................................9

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