Manual Sistema Scada

Alfred Kuhse GmbH
TEL +49(0)4171 798-0 , FAX -117
Operating Instruction Genset Control

Project: Guangopolo II, 5301954
Rev./ Date / Status
0 / 25.11.2013/ Comm. Edition

Project :
Guangopolo II, 5301954
Client
MAN Diesel & TurboSE, Augsburg
Client Order No.:
4500859942 46D
Manufacturer:
Alfred Kuhse GmbH

D 21423 Winsen/Luhe
TEL
+49(0)4171 798-0 FAX -117
E-Mail kuhse@kuhse.de
Kuhse Comm. Number :
461180
Rev./ Date / Status
0 / 25.11.2013 / Comm. Edition
Document No. :
461180_Operation Instruction.doc
Mid voltage level:

Control Voltage:
Auxiliary Voltage:
13,8kV/46kV 60Hz
230V AC, 60Hz; 24 V DC
127/230V AC, 60Hz
461180_Operating Instruction Genset Control Commissioning Edition.doc
Page 1 of 134
Alfred Kuhse GmbH

TEL +49(0)4171 798-0 , FAX -117

Rev./ Date / Status
0 / 25.11.2013/ Comm. Edition
Table of Contents:
Table of Contents: ............................................................................................................. 2
Revision History................................................................................................................. 7
1
Principle Front View ................................................................................................ 8
2
Principle Description............................................................................................. 10
2.1
2.2
3
Purpose ............................................................................................................................................... 10

Properties ............................................................................................................................................ 10
Functional Descriptions of Operation and Indication Elements ....................... 12
3.1
Switches and Push Buttons ................................................................................................................. 12
3.1.1 Selector Switch Operation Mode GCP/SCADA ............................................................................... 12
3.1.1.1 Purpose ............................................................................................................................................. 12
3.1.1.2 Properties .......................................................................................................................................... 12
3.1.2 Selector Switch Alternator Voltage ................................................................................................... 14
3.1.2.1 Purpose ............................................................................................................................................. 14
3.1.2.2 Properties .......................................................................................................................................... 14
3.1.3 Selector Switch Local Synchronization Manual/OFF/Automatic ...................................................... 15
3.1.3.1 Purpose ............................................................................................................................................. 15
3.1.3.2 Properties .......................................................................................................................................... 15
3.1.4 Control Switch Manual Setting Voltage, Power Factor Lower/0/Higher ........................................... 17
3.1.4.1 Purpose ............................................................................................................................................. 17
3.1.4.2 Properties .......................................................................................................................................... 17
3.1.5 Control Switch Manual Setting Speed, Frequency, Load Lower/0/Higher ....................................... 18
3.1.5.1 Purpose ............................................................................................................................................. 18
3.1.5.2 Properties .......................................................................................................................................... 18
3.1.6 Push Button Red Emergency Stop................................................................................................... 19
3.1.6.1 Purpose ............................................................................................................................................. 19
3.1.6.2 Properties .......................................................................................................................................... 19
3.1.7 Push Button Black Acknowledge/Reset ........................................................................................... 21
3.1.7.1 Purpose ............................................................................................................................................. 21
3.1.7.2 Properties .......................................................................................................................................... 21
3.1.8 Push Button Blue Lamp Test............................................................................................................ 22
3.1.8.1 Purpose ............................................................................................................................................. 22
3.1.8.2 Properties .......................................................................................................................................... 22
3.1.9 Push Button Green Alternator CB ON .............................................................................................. 23
3.1.9.1 Purpose ............................................................................................................................................. 23
3.1.9.2 Properties .......................................................................................................................................... 23
3.1.10 Push Button Red - Alternator CB OFF ................................................................................................ 25
3.1.10.1 Purpose ............................................................................................................................................. 25
3.1.10.2 Properties .......................................................................................................................................... 25
3.2
Indications ........................................................................................................................................... 27
3.2.1 Signaling Column ................................................................................................................................ 27
3.2.1.1 Purpose ............................................................................................................................................. 27
3.2.1.2 Properties .......................................................................................................................................... 27
3.2.2 LED Position Indicator Alternator Circuit Breaker ............................................................................ 29
3.2.2.1 Purpose ............................................................................................................................................. 29
3.2.2.2 Properties .......................................................................................................................................... 29
3.2.3 LED Position Indicator Alternator Earthing Switch ........................................................................... 30
3.2.3.1 Purpose ............................................................................................................................................. 30
3.2.3.2 Properties .......................................................................................................................................... 30
3.2.4 LED Position Indicator Alternator Neutral Earthing Switch .............................................................. 32
Page 2 of 134
Alfred Kuhse GmbH

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Rev./ Date / Status
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3.2.4.1 Purpose ............................................................................................................................................. 32
3.2.4.2 Properties .......................................................................................................................................... 32
3.2.5 Voltmeter Alternator Voltage ............................................................................................................ 34
3.2.5.1 Purpose ............................................................................................................................................. 34
3.2.5.2 Properties .......................................................................................................................................... 34
3.2.6 Ammeter Alternator Current ............................................................................................................. 35
3.2.6.1 Purpose ............................................................................................................................................. 35
3.2.6.2 Properties .......................................................................................................................................... 35
3.2.7 Double Voltmeter Synchronization Voltage ...................................................................................... 36
3.2.7.1 Purpose ............................................................................................................................................. 36
3.2.7.2 Properties .......................................................................................................................................... 36
3.2.8 Double Frequency Meter Synchronization Frequency ..................................................................... 37
3.2.8.1 Purpose ............................................................................................................................................. 37
3.2.8.2 Properties .......................................................................................................................................... 37
3.2.9 Synchronoscope .................................................................................................................................. 38
3.2.9.1 Purpose ............................................................................................................................................. 38
3.2.9.2 Properties .......................................................................................................................................... 38
3.3
Units .................................................................................................................................................... 39
3.3.1 Automatic Synchronization Unit .......................................................................................................... 39
3.3.1.1 Purpose ............................................................................................................................................. 39
3.3.1.2 Properties .......................................................................................................................................... 39
3.3.2 Multifunctional Monitoring Unit (MMU) Siemens Sentron PAC3200 ................................................ 41
3.3.2.1 Purpose ............................................................................................................................................. 41
3.3.2.2 Properties .......................................................................................................................................... 41
3.3.2.3 Operation .......................................................................................................................................... 41
3.4
Visualization ........................................................................................................................................ 43
3.4.1 Panel PC ............................................................................................................................................. 43
3.4.1.1 Purpose ............................................................................................................................................. 43
3.4.1.2 Properties .......................................................................................................................................... 43
3.5
Alternator Protection ............................................................................................................................ 45
3.5.1 Alternator Prote ction Device ............................................................................................................... 45
3.5.1.1 Purpose ............................................................................................................................................. 45
3.5.1.2 Properties .......................................................................................................................................... 45
4
Operating Scenarios ............................................................................................. 47
5
Overview diagramms ............................................................................................ 55
6
Engine control functions ...................................................................................... 61
4.1
Synchronization of Circuit Breakers .................................................................................................... 47
4.1.1 Synchronization Principles .................................................................................................................. 47
4.1.2 Synchronization Operating Scenarios ................................................................................................. 48
4.1.2.1 Automatic Synchronization from GCP .............................................................................................. 48
4.1.2.2 Manual Synchronization from GCP .................................................................................................. 49
4.1.2.3 Automatic Synchronization from SCADA ......................................................................................... 50
4.1.2.4 Principle Control and Operating Philosophy Alternator Circuit Breaker and Excitation ................... 51
5.1
5.2
5.3
5.4
5.5
5.6
6.1
6.2
6.3
6.4
6.5
Overall Single line diagram ................................................................................................................. 55

Data structure GCP PLC ..................................................................................................................... 56
Protecion and measuring scheme GCP ............................................................................................. 57
Power Plant Operation modes ............................................................................................................ 58
Front View of Engine Control Panel +ECPx ........................................................................................ 59
Engine Auxiliary Panel +EAPx ............................................................................................................ 60
Push button of engine control at PC touch panel ................................................................................ 61
Start procedure of engine in GCP mode ............................................................................................. 61
Start procedure of engine in SCADA mode ........................................................................................ 63
Local Remote switch 1HZ1012 at engine ......................................................................................... 63
Generator Synchronisation .................................................................................................................. 64
Page 3 of 134
Alfred Kuhse GmbH

TEL +49(0)4171 798-0 , FAX -117

Rev./ Date / Status
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6.5.1 Parameter list for Synchronisation Monitoring .................................................................................... 64
6.5.2 Generator circuit breaker monitoring ................................................................................................... 65
6.6
Load controller description .................................................................................................................. 66
6.6.1 Settings of load controller GCP ........................................................................................................... 66
6.6.2 Monitoring of control function .............................................................................................................. 67
6.7
Loading of Engine................................................................................................................................ 68
6.8
Limitations in load range by the PCU (power control unit) .................................................................. 69
6.8.1 Load reduction dependent on ambient air temperature. ..................................................................... 69
6.8.2 Load reduction because of too high exhaust gas temperature before turbine. ................................... 70
6.9
PCU Parameter list (example) ............................................................................................................. 71
6.10 Further load limitations ........................................................................................................................ 72
6.11 Exhaust Gas Temperature Monitoring ................................................................................................ 73
6.11.1 Functional Description ......................................................................................................................... 73
6.11.2 Exhaust gas temperature monitoring functions ................................................................................... 76
Monitoring maximal value at cylinder ............................................................................................................... 76
Monitoring mean value deviation at cylinder .................................................................................................... 76
Monitoring maximal value before turbo charger ............................................................................................... 77
Temperature value after turbo charger ............................................................................................................ 77
Reset 77
6.12 Charge air temperature control TC6180 with 01MJG32AA010-M01 (MOV003) ................................ 78
6.12.1 Parameter list charge air temperature control ..................................................................................... 79

CHATCO curve ................................................................................................................................. 80
6.12.2 Function of controller ........................................................................................................................... 80

Monitoring of the control valve .......................................................................................................... 80
6.12.3 Selection operating mode .................................................................................................................... 80
Monitoring of the control valve ..................................................................................................................... 80
6.12.4 Allumatic .............................................................................................................................................. 81
Operation Modes ............................................................................................................................................ 81
6.12.5 Calculating the dewpoint temperature in normal mode ....................................................................... 82
6.12.6 Calculating the dewpoint temperature in failure mode ........................................................................ 83
6.12.7 Achievement of the optimal charge air temperature ........................................................................... 83
Allumatic Mode ............................................................................................................................................... 83
CHATCO Mode................................................................................................................................................ 83
6.12.8 Alarms ................................................................................................................................................. 84
6.12.9 Emergency Stop .................................................................................................................................. 84
6.13 HT cooling water control valve 01MJG31AA010-M01 via TC3180 with MOV 002 ............................. 86
6.13.1 Parameter list HT cooling water controller .......................................................................................... 88

Monitoring of the control valve .......................................................................................................... 88
6.14 LT cooling water control valve 01MJG32AA025-M01 TC3202 with MOV004: ................................... 89
6.14.1 Parameter LT cooling water control .................................................................................................... 90
6.15 Slow turn .............................................................................................................................................. 90
6.15.1 Running sequence slow turn ............................................................................................................... 90
6.15.2 Parameter slow turn ............................................................................................................................ 91
6.15.3 Signal progression for direction of rotation recognition ....................................................................... 91
6.16 Ajdusting instruction of software PID-controller .................................................................................. 92
6.17 Splash oil ............................................................................................................................................. 93
6.17.1 General ................................................................................................................................................ 93
6.17.2 Subfunctions ........................................................................................................................................ 94
6.17.3 Monitoring Regarding Maximum Value Exceeding ............................................................................. 94
6.17.4 Monitoring Regarding Mean Value Deviation ...................................................................................... 94
6.17.5 Wire Break ........................................................................................................................................... 95
6.17.6 Not Plausible ....................................................................................................................................... 95
6.17.7 Monitoring active ............................................................................................................................... 95
6.17.8 TIMER (INTERGRATED) .................................................................................................................... 95
Page 4 of 134
Alfred Kuhse GmbH

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Rev./ Date / Status
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6.18
6.19
6.20
6.20.1

6.20.2

6.21
6.21.1
6.21.2
6.21.3
6.21.4
6.21.5
6.21.6
6.21.7
7
Generator power factor controller ........................................................................................................ 96

Testing of shut down valve X-1SZV1012 ............................................................................................ 97
CONTROL OF INTAKE AIR SYSTEM ................................................................................................ 98
Charge Air Blow-off System (xxMJQ61BR010/14) ............................................................................. 98
Interfaces .......................................................................................................................................... 98
Malfunction ........................................................................................................................................ 99
Alarms ............................................................................................................................................... 99
Start requirements ............................................................................................................................ 99
Normal operation: manual local ........................................................................................................ 99
Normal operation: manual remote .................................................................................................... 99
Normal operation: automatic remote ................................................................................................ 99
Normal operation: automatic local .................................................................................................... 99
Parameters Intake Air System ........................................................................................................ 100
General intake air instrumentation .................................................................................................... 101
Interfaces ........................................................................................................................................ 101
Malfunction ...................................................................................................................................... 101
Alarms ............................................................................................................................................. 102
Start requirements .......................................................................................................................... 102
Normal operation: manual local ...................................................................................................... 102
Normal operation: manual remote .................................................................................................. 102
Normal operation: automatic remote .............................................................................................. 102
Normal operation: automatic local .................................................................................................. 102
Princip of auxiliaries Operation modes .............................................................................................. 103
Manual Local Mode Auxiliary Drives ................................................................................................. 104
Manual Remote Mode Auxiliary Drives ............................................................................................. 105
Automatic Remote Mode Auxiliary Drives ......................................................................................... 106
Automatic Local Mode Auxiliary Drives ............................................................................................. 107
Double pumps ................................................................................................................................... 108
Manual pump switching ..................................................................................................................... 109
Double Starter Pumps, Master Selection Philosophy ....................................................................... 109
LV ENGINE Auxiliaries Panel +EAPx ................................................................. 113
7.1
LV ENGINE Auxiliaries Panel +EAPx frontview ................................................................................ 114
7.2
Pre lubrication pump 01MJV21AP030-M01 (P007) on MOD006 ...................................................... 115
7.2.1 Start prelubrication ............................................................................................................................ 115

Parameter Start prelubrication ........................................................................................................ 116
7.2.2 Cooling down the engine in case of shutdown .................................................................................. 116
7.2.3 Parameter: Cooling down function .................................................................................................... 116
7.3
Generator heating 01MKA01AH010 (H100) ..................................................................................... 117
7.4
Cylinder Lubrication 01MKA01AH010 (1EM2470) ............................................................................ 118
7.4.1 Area of application ............................................................................................................................. 118
7.4.2 Vgele System .................................................................................................................................. 118
7.4.3 Process sequence: Cylinder lubrication ............................................................................................ 119

Manual operation "Cylinder lubrication ON" ................................................................................... 119

Manual operation "Running-in mode" ............................................................................................. 119

Automatic operation ........................................................................................................................ 119

Control response in the event of failure of the input signals ........................................................... 119

Parameter: Cylinder lubrication ...................................................................................................... 120
7.5
Nozzle cooling water module 01MJG34AC010 (MOD005) ............................................................... 121
7.5.1 Parameters Nozzle cooling water module X0PAB48AC001 (MOD005) ........................................... 121
7.6
Fuel oil module 01END56AP010 (MOD008), HFO / light fuel oil (LFO)-Operation .......................... 122
Diesel operation ............................................................................................................................................. 122
HFO operation ................................................................................................................................................ 122
7.7
HT cooling water preheating module 01MJG31AP020-M01 (P070 on MOD004) ............................ 124
Page 5 of 134
Alfred Kuhse GmbH

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Rev./ Date / Status
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7.8
7.9
7.9.1
7.10
7.10.1
7.10.2
7.10.3
7.10.4
7.10.5
7.11
7.12
Lube oil separator module 01MJV22AT010 (MOD007 ..................................................................... 125

Lubrication oil valve xxMJV23AA202-Y01 on MOD057 (SOV 2303) ................................................ 126
Value Parameter Lubrication oil valve xxMJV23AA202-Y01 (SOV 2303) ........................................ 127
Power house ventilator 1 / 2 xxUMF15AN010-M01 / xxUMF15AN010-M02 .................................... 128
Normal operation automatic remote .................................................................................................. 128
Operation manual remote Powerhouse ventilation system ............................................................ 129
Operation manual local Powerhouse ventilation system................................................................ 130
Malfunctions ...................................................................................................................................... 131
Alarms ............................................................................................................................................... 132
DO Shut Off Valve Before Booster Module 01EGD53AA202-Y01 ................................................... 133
HFO Shut Off Valve Before Engine 01END56AA202-Y01 ............................................................... 133
Page 6 of 134
Alfred Kuhse GmbH

TEL +49(0)4171 798-0 , FAX -117

Rev./ Date / Status
0 / 25.11.2013/ Comm. Edition
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Page 7 of 134

Rev./ Date / Status
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PRINCIPLE FRONT VIEW

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Panel label
Voltmeter alternator voltage
Ammeter alternator current
Double voltmeter synchronization voltage
Double frequency meter synchronization frequency
Synchronoscope
Selector switch alternator voltage
Multifunctional monitoring unit (MMU)
Automatic synchronization unit
Panel PC
Push button blue lamp test
Push button black acknowledge/reset
Push button red emergency stop
Control switch manual setting voltage, power factor lower/0/higher
Control switch manual setting Speed, frequency, load lower/0/higher
Selector switch local synchronization manual/OFF/automatic
Selector switch operation mode GCP/SCADA
LED position indicator alternator circuit breaker
Push button green alternator CB ON
Push button red alternator CB OFF
Alternator protection device
LED position indicator alternator neutral earthing switch
Signaling column red = engine stopping/standstill
Signaling column yellow = genset alarm
Signaling column green = engine starting/running
LED position indicator alternator earthing switch
Top filter
Filter ventilator

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Page 10 of 134
Alfred Kuhse GmbH

TEL +49(0)4171 798-0 , FAX -117

Rev./ Date / Status
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Page 11 of 134
Alfred Kuhse GmbH

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3
FUNCTIONAL DESCRIPTIONS OF OPERATION AND INDICATION
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3.1
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3.1.1
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Rev./ Date / Status
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OVERVIEW DIAGRAMMS
5.1
Overall Single line diagram
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5.2
Data structure GCP PLC

134
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5.3
Protecion and measuring scheme GCP
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5.4
Power Plant Operation modes
Grid voltage and frequency variation on the busbar shall not exceed normal +/- 5%.
Manual start order for each / of all gen.-sets.
Automatic synchronizing of alternators, mains feeder will synchronize by costumer.
Parallel operation of Power Plant with grid, with adjustable values of active and reactive
Load for each gen.-set.
In the event of grid failure during grid parallel operation, decoupling from the grid within an
extremely short time for safe operation of the power plant.
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5.5
Front View of Engine Control Panel +ECPx
This switchboard consists of 2 panels and stands in the engine hall. All the engine sensors are connected to this
switchboard and collected in a control device for sending via Profibus-DP cord to +GCPx and to +EAx panel.
The engine governor are incorporated in this panels and the generator regulator (AVR) is installed.
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5.6
Engine Auxiliary Panel +EAPx
This switchboard is delivery part of costumer, stands in the engine hall. All the engine auxiliaries are connected
to this switchboard and collected in a control device for sending via Profibus-DP cord to +GCPx.
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ENGINE CONTROL FUNCTIONS
6.1
Push button of engine control at PC touch panel
Blocking engine start

Release engine start
Start engine
Stop engine
Push button Blocking engine start:

By pressing this push button is the engine start blocked, no engine start is possible. It is active in all modes
(GCP, SCADA or Local mode).
Push button Release engine start:
By pressing this push button is the engine released for remote or local start depending of selected operation
mode GCP, SCADA or Local (at engine)
Push button Start engine:
This push button is released if the push button Release engine start is activated, operation mode GCP is
selected and the local switch at engine is in remote position. By pressing the engine will start automatically at
first the start conditions are requested and if they are fulfilled, pressing again causes the engine to be
started.
Push button Stop engine:
This push button is released in operation mode GCP and the local switch at engine is in remote position. By
pressing this push button the engine stopped automatically.
Function of selector switch 66S6 operation mode:
In position GCP, the genset can be requested using the Manual Start/Stop button from the PC677B and the
gen. CB contol push buttons on/off at the mimic diagram is relesed.
In position SCADA, the genset can be requested from the DCS system.
6.2
Start procedure of engine in GCP mode
By pressing the "Start" button the start conditions are requested.

The auxiliary drives for the start requirements are requested at the same time.
The following auxiliary drives are switched on:
(local mode),
1. Pre-lubrication oil pump X0MJV21AP030 (P007)
2. Release speed controller
3. Request fuel module
4. Test shut down valve X-1SZV 1012
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The following conditions must be met for start release:
Prelubrication time of T = 1 minute expired. (Exception: Start prelubrication is not necessary, if the standstill
time is less than the adjustable time (Max. standstill time start prelubrication is required).
No shutdown fault active.
The turning gear not engaged. (FE46)
X-1PSH2170 lube oil pressure engine start release (0,3bar) dyn.
X-1PSH3170 cooling water pressure high (2bar), dyn.
No X-1SZV1012 emergency stop valve fault (FE102)
No Slow turn fault, purging necessary (FE148)
If the start-up conditions are met, this is displayed by the LED START RELEASE .
If the start conditions are fulfilled, pressing again causes the engine to be started.
The engine can be shut down by pressing STOP.
The start-up air valve (X-1SSV1011) is opened.
If the diesel engine does not attain the ignition speed, or START is not activated, the starter valve is closed.
If the diesel engine does attain the ignition speed, the LED START CONTROL go out and the following
auxiliary drives are selected:
1. Cylinder lubrication 1EM2470
cylinder lub. oil pump)
Once the engine is run-up, the excitation must be switched on manually.
When the nominal voltage and frequency are reached and the waiting time for load release has expired, the
generator protection circuit breaker can be switched on. In order to do this, press the push button GENERATOR
ON (button in the mimic diagram). The automatic unit then asks whether a generator or the mains coupling
circuit breaker is switched on. If the interlocking condition is met (no generator on and the mains coupling circuit
breaker is off), the generator circuit breaker is closed directly.
If the interlocking condition is not met, the automatic unit selects synchronisation. This selection is indicated by
the activation of synchronoscope and the flashing generator circuit breaker acknowledgement. The
synchronisation system establishes the synchronous condition and directly switches on the generator protection
circuit breaker (provided that the syn. selector switch is in the Automatic position)
After successfully closing of circuit breaker, the automatic unit turns the synchronisation off again. The genset
can only be loaded as settable limit value for manual operation. The automatic power controller is active,
loading is limited to the permissible value.
Pressing the push button GENERATOR CB OFF directly opens the generator circuit breaker.
The genset is switched off again by pressing of push button Stop.
The following genset auxiliary drives start a idle run time to cool down the engine.
1. Pre-lubrication oil pump P007
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6.3
Start procedure of engine in SCADA mode
In position DCS the genset can be from the DCS system.

If the genset is requested (is displayed via LED START DEMAND), the start-up preconditions are selected
as in manual operation.
If the start-up preconditions are met (see Start procedure of engine in GCP mode), the genset will be
started.
If the engine is running, DCS must give the signal ALTERNATOR CB ON. Then the automatic unit selects
synchronisation. The synchronisation system establishes the synchronous conditions and directly switches on
the generator circuit breaker. The generator power controller (for the loading and unloading criteria please
refer to the description of the load controller) is now activated with the status signal Generator CB is on.
If the genset is deselected, the load of the generator will be automatically reduced. After this, the generator
circuit breaker is opened and the genset will be shutdown after an idle run time.
6.4
Local Remote switch 1HZ1012 at engine
This switch is used for commissioning. In local position is the Start pus button 1HOS1011 at engine
released. By first pressing the engine start preconditions are requested, after the start preconditions are
fulfilled the engine can start, after a second press the engine will start in idle mode.
-
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6.5
Generator Synchronisation
The following functions can be preselected using the synchronisation selection switch 232S3:
1- Automatic
0- off
2- Manual
These selections are only available in GCP position. In SCADA position is generally the automatic synchronising
function selected independently of the position of synchronisation selection switch.
Position 0 off
In this position, no synchronisation selection takes place.
Position 1 - Automatic Synchronisation
In this position, the automatic synchronisation device SPM is switched on. The SPM now provides the
synchronism by modifying the engine speed. Once synchronisation is established, the SPM discontinues the
synchronisation command. The generator c.b. is directly closed by this switch on command. If the c.b. closed
successfully, the synchronisation is aborted. The automatic synchronisation can be monitored by the
synchronoscope.
(Adjustment of the SPM see separate description)
The synchronisation time is monitored. If the synchronisation is requested and the selected time has passed,
then this is displayed as fault signal.
Position 2 - Manual Synchronisation
In this position, the synchronoscope is switched on. Now, with the help of the speed adjustment push button, the
generator frequency must be manually adjusted to the bus bar frequency. Rough speed adjustment can be
made by comparing both frequencies (double frequency meter). If both frequencies are about the same, then
one can fine-tune by watching the synchronoscope. If the synchronoscope LEDs are still moving very slowly,
then no more adjustment command should be given. Now the connection can be made by hand.
If the generator c.b. closed successfully, then the synchronisation is aborted.
In order to avoid faulty synchronisation a synchr. check relay integrated in the LED synchronoscope. The green
LED at the top indicates the synchronisation release.
The speed adjustment push button in the +GCP panel is only released during the synchronisation.
The generator voltage is also compared with the mains voltage by the generator regulator. This control is carried
out in order to keep the switch-on peak as low as possible.
CAUTION
1. Please, ensure that before leaving the station, the selector switch for synchronisation is switched back to
Automatic.
6.5.1
Parameter list for Synchronisation Monitoring
Description
Synchronisation monitoring
Dimension
Basic setting
min:sec
02:00
Setting after
taking into
operation
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6.5.2
Generator circuit breaker monitoring
Generator switch off fault

The fault signal comes up when the PLC wants to switch off the generator c.b. but fails to switch off after
command. When this message is displayed, and a stopping fault occurs, then the mains coupling c.b. is
switched off.
Generator switch on fault
The fault signal comes up when the PLC wants to close the generator c.b. but fails to close after command
and after a delay of one second.
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6.6
Load controller description
6.6.1
Settings of load controller GCP

Dimension
Basic setting
1
2
Page 1
Nominal value from CCP
Nominal value SCADA
%
%
Indication
100
3
4
Actual nominal value

Actual load (electrical)
%
%
Indication
Indication
5
6
7
8
Dead band
Proportional area Xp
Pulse length
max. pause
%
%
sec
sec
1
30
0,5
2.0
9
10
11
Gradient nominal value

Gradiant manual operation
Gradiant SCADA operation
%/s
%/s
%/s
1
1
0,5
12
13
14
15
Unloading value
Del. Load reg. Fault
Release load inc. after change fuel oil
Nominal load (electrical)
%
sec
sec
kW
10
300s
30
8370
16
17
18
19
20
21
%
%
%
%
%
%
%
kw
65
60
75%
70
70
70
97,5
8954
24
25
26
27
28
29
30
31
32
33
34
35
Max. load exh. Gas temp. red.

Max. load gen. winding temp. red.
Max. load turbocharger speed red.
Max. load splash oil monitoring
Max. load change fuel oil
Max. load fuel oil viscosity
El. efficiency
Nominal load (mechanical)
Page 2
Actual mechanical load
Exh. gas temp. load reduction
Hysteresis
Step width load dec/inc.
Load inc/dec period exh.
Lower load point (default)
Max. load (overload mont.)
Max. load (exh. gas temp.)
Max. load (air intake)
Max. load derating by speed (normal)
Max. load derating by speed (overload)
Max. load (lub. oil temp.)
%
C
C
%
s
%
%
%
%
%
%
%
Indication
560
5
1
120
90
Indication
Indication
Indication
100
100
100
36
Max. permitted load elec.
100
23
see acceptance
certificate
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37
47
Min. load gen. set

Maximum allowed eng. Power
intake air temperature before TC
Set point 1 air temp. intake
Set point 1 load
Set point 2 load
Set point 3 load
Set point 4 load
Page 3
Set point 5 load
48
49
50
51
52
Load control warming up process

1 Warming up set point 1
2 Warming up period step 1
%
s
%
s
s
5
180
30
0
240
53
54
55
56
57
58
59
60
Load increasing without preheating

%
s
%
s
s
%
s
s
5
60
30
480
0
3400
30
60
Start derating by underspeed (normal)

Gradient derating by underspeed (normal)
Start derating by underspeed (overload)
Gradient
derating
by
underspeed
(overload)
Start derating by overspeed (overload)
Gradient derating by overspeed (overload)
%
%
%
%
100
1
105
1
%
%
102,5
2,5
Lube oil temp. load red.

Hysteresis
Step width load dec/inc
Page 4
C
C
%
70
3
2
s
%
5
85
38
39
40
41
42
43
44
45
46
61
62
63
64
65
66
67
68
69
70
71
6.6.2
40
C
%
C
%
C
%
C
%
C
15
100
20
100
21
99,5
30
95,2
40
90,4
to
Monitoring of control function
The load control failure signal arises when the actual value for the set time is beyond the dead zone.
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6.7
Loading of Engine
The loading of the engine will be done by curve Shortest possible continus loading (without Jet Assis)
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6.8
Limitations in load range by the PCU (power control unit)
PCU is a Software-System, which limits the maximum power delivery of the engine dependant on
surrounding conditions:
Load reduction dependant on the ambient air temperature
Load reduction because of unacceptable mechanical overload and speed difference
Load reduction because of too high exhaust gas temperature before turbo charger
The permitted load calculated by the PCU always represents the mechanical load to the engine coupling.
6.8.1
Load reduction dependent on ambient air temperature.
The permitted long-term performance is defined by the compatible limit curve. This curve is established in
the form of support values (table). By fixing up to 5 temperature support values, the limit values for the longterm performance are interpolated each linearly.
The establishing of the actually permissible performance is made in direct dependence of the ambient air
temperature.
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6.8.2
Load reduction because of too high exhaust gas temperature before turbine.
In case of excess of a pre-set limit value (e.g. 550C), the permitted load is gradually reduced by steps of 1%
of the nominal load until the temperature limit value is undershot, taking into consideration a steady state
time of 2 minutes. In case the temperature falls lower than 5C (set value), the load can be released again in
1% steps until a limit value is reached after the point 1 or 2 of the permitted load.
REMARKS
All three-load reduction possibilities are always fundamentally calculated through. It is always the
lowest that sets the permitted engine load output.
The load reductions are limited to Pmin (specific to the plant limit value, or default value). As far as an
internal fault in the PCU leads to it, then no maximum permitted load is calculated any more (e.g.
Failure of the ambient temperature sensor), then the higher-ranking load control must reduce the
load of the engine to Pmin on safety grounds.
In order to render load reduction transparent to the client, the following information are visualised on a
display:
Results of the PCU calculation:
Display of the maximum permitted mechanical load because of load monitoring
Display of the maximum permitted load because of exhaust gas temperature
Display of the maximum permitted load because of ambient air temperature
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6.9
PCU Parameter list (example)
Page 2
El. Efficiency
Nominal load (mechanical)
Act. Mechanical load
Period monitoring overload
Max. overload per period
Delay overload operation
Remaining time overload
Exh. Gas time load reduction
Hysteresis
Step with load dec/inc
Max. load (overload monit.)
Max. load (exh. Gas temp.)
Max. load (air intake)
Max. permitted load elec.
Derating by speed (normal)
Derating by speed (overload)
Dimension
Basic setting
%
kW
%
min.
min.
sec
min.
C
C
%
min.:sec
%
%
%
%
%
%/%
%/%
97,3
8370
Display
0
20
20sec
Display
555
5
1
120sec
90
Display
Display
Display
Display
1
1
see acceptance
certificate
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6.10 Further load limitations

Additionally to the PCU, the following events can lead to load limitations:
Fault signal from the monitoring of the exhaust gas temperature behind cylinder.
Max. load of gen. Overtemp.
X-1SZH1004A turbocharger speed max. load red.
X-1SZH1004B turbocharger speed max. load red.
X-1TAHHU001 generator winding overtemp. -A Red.
X-1TAHHV001 generator winding overtemp. -A Red.
X-1TAHHW001 generator winding overtemp. -A Red.
If one of the above named monitoring reacts, then the load is reduced to a pre-settable value (Lower load
point). Only when the corresponding fault signal is quitted, full load operation will be released.
A message Actual engine nominal load exceeded (FE111) is created from the error messages that cause a
reduction in power, see the error message bar or generally if an engine overload exists.
This message serves to warn the operator that the load must be reduced or another machine started as
quickly as possible.
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6.11 Exhaust Gas Temperature Monitoring

6.11.1 Functional Description
This control monitoring of the exhaust gas temperature is part of MAN Software.
Purpose of the herein described software module Exhaust Gas Temperature Monitoring is the monitoring
of the exhaust gas temperatures of a Diesel power plant engine. Always the software module must be
integrated into another software program.
The temperatures are measured by Type K sensors. This means that the exhaust gas temperatures are
monitored indirectly and digitally by software.
The monitoring process is always active, independently from the current operating state of the corresponding
engine (running or not running).

Image 1.0 shows an example of an exhaust gas temperature monitoring module within a SCADA
visualization.

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6.11.2 Exhaust gas temperature monitoring functions

Several sensors measure the current absolute value of the exhaust gas temperature constantly. Measuring
points exist at every cylinder of an engine and at the turbo charger. All measured values are analysed by the
PLC. Depending on the result of every analysis the PLC sends signals to other software modules, e.g. a
SCADA visualisation.

The exhaust gas temperature monitoring is divided into the following sub functions.
Monitoring maximal value at cylinder

Each sensor monitors the exceeding of the allowed maximal value.
The following criteria are monitored:

If the measured value exceeds a predefined first temperature limit, the alarm signal PRE ALRAM will be
generated and sent to the SCADA visualisation.

If the measured value exceeds a predefined second temperature limit, the signal ENGINE LOAD
REDUCTION will be sent from the PLC to the SCADA visualisation and other software modules within the
PLC.
Monitoring mean value deviation at cylinder

The PLC calculates a mean value of all temperature measuring sensors with status plausible -. Basis for
the calculated mean value are the present absolute values. Further on the PLC calculates for every sensor
the deviation of the absolute value from the mean value. This is necessary to prevent that the temperature at
a single measuring point deviates too much from the calculated mean value.

If the calculated deviation exceeds a first temperature limit, the alarm PRE ALARM MEAN SENSOR will be
generated and sent to the SCADA visualisation.

If the calculated deviation exceeds a second temperature limit, additionally the alarm ALARM MEAN
SENSOR is generated and sent to the SCADA visualisation. Optional the signal ENGINE LOAD
REDUCTION will be sent from the PLC to the SCADA visualisation and other software modules within the
PLC.

A second temperature limit is only active if the corresponding genset is running with a load of more than 60
% (default value). The default value can be changed.
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Monitoring maximal value before turbo charger

The exceeding of the allowed maximal value is monitored.
The following criteria are monitored:

If the measured value exceeds a predefined first temperature limit, the alarm signal PRE ALRAM will be
generated and sent to the SCADA visualization.

If the measured value exceeds a predefined second temperature limit the alarm signal ALARM SENSOR will
be sent from the PLC to the SCADA visualization. The signal ENGINE LOAD REDUCTION will be sent to the
SCADA visualization and other software modules within the PLC.

If the measured value exceeds a predefined third temperature limit, the signals OVERTEMPERATURE
SENSOR and ENGINE SHUTDOWN will be created and sent from the PLC to the SCADA visualization and
other software modules within the PLC.
Temperature value after turbo charger

At this measuring point no monitoring of the exhaust gas temperature takes place. But the measured
absolute value of the present exhaust gas temperature is sent to the SCADA visualization constantly.
Reset
All generated alarm signals are no longer active if the following conditions are given:
7KHSUHVHQWDEVROXWHYDOXHDWDPHDVXULQJSRLQWKDVIDOOHQEHORZWKHUHOHDVLQJWHPSHUDWXUHOLPLW
RQFHDJDLQ
$VRIWZDUHUHVHWZDVGRQH
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6.12 Charge air temperature control TC6180 with 01MJG32AA010-M01 (MOV003)
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Released operation modes:
Automatic functions:
With charge air temperature control, the fluid flow of LT cooling water via the charge air cooler is controlled.
The reference value for charge air temp. is a linear function of the ambient temperature, measured by the air
intake temperature of the engine.
The controller is released by a load limit high (list of GCP limit values) to prevent condensating in the charge
air cooler.
Manual functions:
In this function the valve can be controlled by push buttons in direction Open and Close
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6.12.1 Parameter list charge air temperature control

act.
ambient
temperature
2TE6100
act. charge air temp. 2TE6180
act. nominal charge air temp.
calculated output
Unit
C
Basic setting
indication
End setting
indication
C
C
%
indication
indication
indication
indication
indication
indication
Nominal value preheating

Actual nominal value from ambient
temperature
Actual
nominal
value
from
Allumatic
Set point 1 ambient temperature
Set point 1 nominal value
C
C
85
indication
indication
C
C
C
C
C
C
16
42
28
56
48
42
Ambient air pressure

Charge air pressure before cyl.
1PT6100
mbar
mbar
1000
indication
Gain
Integration time
Dead zone
Minimum manipulated variable
Impulse time
Pause time
ms
%
%
ms
ms
3
1m
1
0
1s
5s
Action time control valve

act. valve position
Delay controller failure
sec
%
s
Pulse time minus

Pulse time plus
indication
2m40s
indication
200
2
2
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CHATCO curve
Example, pls. look MAN requirements for the used engine
6.12.2 Function of controller
Monitoring of the control valve
The error message X-1TC6180 Chatco c.w. control fault is created, if the control value is recognised as
failed.
6.12.3 Selection operating mode

Following modes are selectable:
Automatic
Manual
Position Automatic:
In this position automatic control is released as described previously.
Position Manual:
This position is intended for service purposes. In this mode are to sets of push buttons selectabele:
Valve command Open and Close
Valve command Open and Close by pulses
Valve command Open and Close
By pressing the button Open, the valve goes in open position. By pressing the button Close, the valve goes
in close position.
Valve command Open and Close by pulses
By pressing the button Open, the valve goes one step in open position. By pressing the button Close, the
valve goes one step in close position.

The error message 1TC6180 Chatco c.w. control fault is created, if the control value is recognised as
failed.
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6.12.4 Allumatic
Automatic Charge Air Control
AlLumatiC CHARGE AIR TEMPERATURE CONTROL
The requirement of the Allumatic-System is to control the charge air temperature regarding to its dewpoint,
i.e. to keep the charge air temperature as low as possible but still high enough so the air bonded water vapor
will not condensate.
The setpoint of the charge air temperature is the charge air dewpoint temperature before cylinder + 1C
(safety margin).
The lower the charge air temperature the lower is the NOx value and also the fuel oil consumption of an
engine.
The airbonded water vapor reduces the NOx value also.
In case of fault by the Allumatic system, a switch over to CHATCO (charge air control depending of the
ambient air temperature) is necessary.
Operation Modes
The operation modes of the Allumatic are Manual Remote and Automatic Remote
Manual Remote
This mode has to be selected at SCADA by soft touch buttons. With these the operator can move the valve
between the position A-AB (heat exchanger active cooled) and B-AB (heat exchanger bypassed).
Automatic Remote
The software controller is active with LT cooling water pump P025.
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6.12.5 Calculating the dewpoint temperature in normal mode

The dew point temperature signal of the intake air unit is available.
The relative humidity measured at 1/2/3HE6010 and the temperature measured at 1/2/3TE6010 at
the manifold of the intake air unit will be measured in CCP by 1/2/3TT6010 1/2/3HT6010.
These result for calculation of tdAns will be transferred to the GCP-PLC. Pls. see description of CCP
item Calculating the dew point temperature for charge air temperature control in genset PLC.
Ambient Air Pressure of 1100 mbar depends on the height of 27m above sea level..
Charge Air Pressure measured by1PT6180 an analog value of 4-20mA will be installed at each
engine.
Charge Air Temperature measured by 2TE6180A, a PT100 resistor will be installed at each engine.
With the help of these values the dewpoint temperature td before cylinder will be calculated.
tdAll =
Pvz
PAns
tdAll
tdAns
=
=
=
=
4102,99
p
ln p vZ
t dAns + 237 , 31 Ans
4102 , 99
charge air pressure before cylinder

charge air pressure before cylinder
dewpoint temperature before cylinder
released temperature before cylinder
237,431
4150 [mbar]
[mbar]
[C]
[C] from CCP
With the result of calculation the charge air temperature can be defined.
- Setpoint for charge air temperature = tdAll dewpoint temperature before Cylinder +1K
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6.12.6 Calculating the dewpoint temperature in failure mode

The dewpoint temperature signal of the air intake unit is not available.
If the dewpoint temperature signal fails, (the analogue value of TT6010 is under 4mA or over 20mA) the
PLC has to switch over to CHATCO. In this mode the charge air temperature is controlled by a
programmed function of the ambient air temperature, measured by 1TE6000.
6.12.7 Achievement of the optimal charge air temperature

To reach the calculated charge air temperature, the valve MOV003 (1TCV6180) must be actuated to flow
through the heat exchanger or to bypass it.
By supplying the charge air cooler with cold water from the LT circuit, the charge air temperature will
decrease, depending on the water flow rate.
Allumatic Mode
The PLC moves the valve to position A-AB in case of temperature value at 2TE6180A is higher than
the dewpoint temperature value before the cylinder +1C
The PLC moves the valve to position B-AB in case of temperature value at 2TE6180A is lower than the
dewpoint value before the cylinder +1C.
CHATCO Mode
The PLC regulates the valve between position A-AB and B-AB regarding to the temperature value at
intake air temperature sensor 1TE6000.
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6.12.8 Alarms
wire break of 1TE6000; 1PT6180; 2TE6180A

Charge air temperature increase over 60C at engine load index >35%
Charge air temperature decrease under 40C
charge air temperature decrease below the dewpoint temperature before cylinder
Position indicator at MOV003 (1TCV6180) indicates Position Charge Air Cooler bypassed, but
the charge air temperature is more than 1C above the dewpoint temperature before cylinder.
Unit failure of TT6010
6.12.9 Emergency Stop
In case of emergency stop of the engines, the PLC forces the valve into position B-AB.
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6.13 HT cooling water control valve 01MJG31AA010-M01 via TC3180 with MOV 002
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Automatic functions:
The use of this technically advanced control system is necessary as the temperature stabilisation of todays
increasingly complex cooling water systems can no longer be handled with simple means.
This description of HT temperature control applies to cooling water systems which are shown in the PID
diagram from MAN.
With this control system, the cooling water temperature behind the mixing point (in front of the engine with
PT100 sensor) is constantly controlled so that the temperature at the engine outlet (PT100 sensor 3TE3180)
corresponds to the reference value of the engine. The reference value at the mixing point is adapted
depending on the engine load calculated according the turbo charger speed.
The control system basically works in the same way as cascade control with a precalculation of the reference
value via disturbance signals for the internal control circuit (see sketch below).
This temperature controller is released by engine operations.
The inner control circuit controls the HT cooling water temperature in front of the engine and the charge air
cooler (at the mixing point, see value analogue values, (TE3165) HT c.w. temp. bef. P002 to a reference
value which it received from the precalculation of the reference value. This reference value is corrected by
the external control circuit (W1 = Wv + Y2).
The outer control circuit thus controls the HT cooling engine temperature after the engine.
Inner control circuit:
As the inner control circuit measures the temperature at the mixing point, temperature fluctuations are
quickly detected in the inflow (or backflow of the engine) and can be corrected immediately.
Outer control circuit:
The correction value of the outer control circuit is adjusted at regular time intervals (tC) . In detail, this
functions as follows:
After the time tC the correction value Y2 is changed by a fifth of the still existing deviation (Xd2) of the actual
value after engine (X2) of the reference value after engine (W2).
The correction time tC must be set so that is greater than the water circulation time of the system. It may not
be an integral multiple of the value. This is required in order to prevent the control circuit from becoming
unstable. The integration of the controller is thus gradual.
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The correction value is limited to Y2max so that the reference value W1, in case of control parameters which
are not set optimally, is not too far. This prevents instability of the control circuit. If larger corrections than
Y2max are required, the characteristic curve (temperature difference T between the mixing point and the
engine outlet is a function of the actual load of engine) is not set correctly for precalculation of the reference
value.
Precalculation of the reference value:
Precalculation of the reference value is used to be able to respond quickly to changes in load or changes in
the flow rate without having to wait for the considerable downtime of the control paths.
The precalculation of the reference value is carried out primarily with the actual load signal. The reference
value at the mixing point is calculated in advance from the reference value after the engine via a
characteristic curve determined (by measurement) during a trial run and on commissioning, which specified
the temperature difference T between the mixing point (in front of the engine and the charge air cooler)
and the engine outlet as a function of the actual load: Wv = W2 - T
If the characteristic curve is set more exactly, the overlaid (outer) control circuit only needs to correct minor
remaining deviations.
A sudden change in load results in a change in temperature with some delay due to the inertia of thermal
systems (heat transmission time tHT). For this reason, the actual load may not be directly processed as input
signals for control, but must first be delayed in time by means of a filter element.
On the other hand, the control must also be carried out in a short amount of time. This is necessary as the
cooling water requires a particular amount of time (tF) to flow from the mixing point to the charge air cooler.
With long pipes between the mixing point and the charge air cooler, the time set for the filter element is
somewhat reduced (tPT1 = tHT - tF).
This temperature controller is released by engine operations.
The temperature controller takes care of all the control tasks (controller 1, controller 2 and precalculation of
the reference value). It only requires the appropriate input signals to do this:
Actual value W1 at the mixing point (Pt100 resistance thermometer, see value eng. inlet cw. temp.)
Actual value W2 after engine (Pt100 resistance thermometer 3TE3180 cyl. c.w. temp. beh. Engine)
Actual load signal, calculated in the load controller
Actual turbo charger speed signal
Manual functions:
In this function the valve can be controlled by entering a set point in percentage Set point for manual
operation. The controller will move then to this set point.
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6.13.1 Parameter list HT cooling water controller

The parameters used in the description are listed here as examples:
ID Description
Unit
Basic setting
1 Nominal value temperature W2 (3TE3180)
C
2 Actual nominal value temp. W1
C
indication
3 Actual value HT temp. behind eng. 3TE3180
C
indication
4 Actual value HT temp. eng. inlet
C
indication
5 Set point for manual operation
%
6 Controller output
%
indication
7 Actual pos. temp. control valve
%
indication
8 Gain
9 Integration time
s
10 Dead zone
%
11 Minimum manipulated variable
%
12 Impulse time
ms
13 Pause time
ms
14 Actuator runtime
min
15 Delay controller failure
s
16 Delay time PT2 turbo speed
s
17 Limit offset Y2 behind endine
C
18 Interval for calculate Y2 offset
s
19 Offset Y2 per interval
%
20 Offset Y2
C
21 Turbo speed set point 1
rpm
22 Temperature difference 1
C
rpm
C
rpm
C
rpm
C
rpm
C
31 Actual temperature difference
C
32 Engine speed set point 1
rpm
33 Flow factor KF-1
34 Engine speed set point 2
rpm
35 Flow factor KF-2
36 Actual flow factor KF
Final setting
90
Calculated value
Actual value
Actual value
Actual setting
Calculated value
Actual value
-2
30
0,3
0
100
500
1,33
120
3
3
15
3
Calculated value
2500
2
4000
5,5
7500
10,5
9500
18
12000
28,5
Actual value
250
1
500
1
Actual value
The error message 1TC3180 HT c.w. control valve fault is created, if a control value is recognised as
failed.
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6.14 LT cooling water control valve 01MJG32AA025-M01 TC3202 with MOV004:
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
The LT cooling water control is realised with a PI controller in PLC.

The actual value is provided by a PT100 measuring point TE 01MJG32CT220, the reference value is
defined in the controller by software.
The control parameters must be adjusted to the control path in situ.
Following modes are selectable:
Automatic
Fixed value
Position Automatic Remote:
In this position automatic control is released as described previously.
Position Manual Remote:
In this function the valve can be controlled by entering a set point in percentage Set point for manual
operation. The controller will move then to this set point.
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6.14.1 Parameter LT cooling water control

Nominal value preheating temp.
Actual nominal value
Actual value 01MJG32CT220
Manual operation
Controler output
1MOV004 position temp. control valve
Start value temperature
Warm up time
Idle run time
Gain
Integration time
Nominal value gradiant
Dead zone
Minimum manipulated variable
Impulse time
Pause time
Actuator run time
Delay controller failure
Unit
C
C
C
%
%
%
C
C
s
Basic setting
indication
indication
indication
26
38
s
%/s
s
%
s
s
s
End setting
32,0
Actual value
Actual value
Actual setpoint
Actual value
Actual value
25,0
50,0
10,0
-1,00
150
20
1
0
1,0
1,0
180
200,0
6.15 Slow turn

The slow turn function is designed for installations with several engines; it prevents liquid in the cylinder at
the start of the engine. This function runs principally like the control of the starting air at the starting process,
but over a more suitable pressure regulation valve with pressure reduction for slower engine speed.
6.15.1 Running sequence slow turn

This function is called for after the request for start and ending of the start pre-conditions, in case the
standstill period exceeded 4 hours.
The progression is as follows:
1. Switching off the speed regulator
2. Triggering both slow turn valves (in order to reduce the starting air pressure (30bar) to slow turn
pressure, which is low enough to ensure that in case there is liquid in the cylinder, the engine does
not turn anymore and to lock the main starting valve).
3. Start of the waiting time t1, in order to decrease the high pressure in the starting air present in the
pipes to slow turn pressure.
4. Exiting of the starting valve X-1SSV1011 (display slow turn in the illustration measuring points
eng.) The revolution counter starts (2,5 revolutions) and set the time function element t2 for the
monitoring of the revolution counter.
5. The revolution count ensues over two sensors, which supply their signals to the controls phaseshifted. This makes detection of speed as well as a direction of rotation possible.
The revolution counter is increased or decreased during the slow turn phase according to the
revolution direction.
6. Once the time function element t2 has run and the prescribed revolution count is not attained, there
is
an
irregularity
in
the
progression
of
the
slow
turn
function.
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The error signal slow turn error appears and the function slow turn is interrupted. The triggering of
the slow turn valves and of the starting valve are cancelled.
7. In case the prescribed number of revolutions is attained within a period of time t2, which is shorter
than the minimal set limit value Tmin, then a slow turn error signal and the function slow turn is
interrupted.
8. Otherwise, the proper start of the engine can follow. The slow turn valves are set back and the
speed regulator is released, the starting valve remains exited, ready for the following start. The time
counter for the standstill time of the engine is set back and the engine starts.
Remark: In case a slow turn has happened, the user must there and then manually remove the liquid from
the cylinders by turning the engine with the help of the turning gear with opened indicating taps. Blowing
through is not permitted. In case this is not carried out, a slow turn error will happen again automatically
when a new start is attempted. The program tries in every case to successfully end a slow turn procedure.
6.15.2 Parameter slow turn

Parameter
Slow turn air pressure
Revolution counter
Time function element t1 for pressure decrease
Time function element t2 slow turn monitoring
Minimum time Tmin for slow turn
Engine standstill time
Values
9-14 bar (according to engine), mechanically
adjustable
2,5U
2s
40s
15s
4h
6.15.3 Signal progression for direction of rotation recognition

The signal progression in case of forward rotation
X-5SE1000
X-1SE1000
Signal progression in case of backward rotation

X-5SE1000
X-1SE1000
The forward rotation always strokes the ascending flank of 1SE 1000 on a 1-signal of 5 SE 1000.
In a backward rotation, this would be the descending flank.
For the BACKWARDS rotation direction, this would be the descending flank.
Legend:
X-1SE1000 = revolution count sensor
X-5SE1000 = revolution count sensor for slow turn
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6.16 Ajdusting instruction of software PID-controller

Pls. look at this file Simatic Standard PID Control_Stdpid_e.pdf in folder Operation instruction.
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6.17 Splash oil
6.17.1 General
The control system Splash-Oil temperature monitoring and supervision considered the
crank gear temperatures.
This system measures the temperatures of the splash oil which is collected on the insides
of the individual crankcase covers via collecting channels PT100 sensors. Than the crank
gear temperatures are monitored indirectly.
The supervision function is activated after engine turns higher than a defined speed or if
the mean temperature is over a defined value and remains active until engine standstill.
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6.17.2 Subfunctions
The SPLASH OIL temperature monitoring is divided into the following sub functions
6.17.3 Monitoring Regarding Maximum Value Exceeding

For each sensor the exceeding of the maximal value is supervised.
The following criteria are for supervision:
- If the measured value in the range of values, no alarm is generated
- Value under the pre alarm border the bar graph is green
- If the measured value exceeds the first temperature limit and elapsed a certain time
with 3 seconds, the alarm "Splash Oil Pre Alarm is generated.
- Value from the pre alarm border the bar graph is yellow
- If the measured value exceeds the second temperature limit and elapsed a certain time
with 3 seconds, additionally the alarm "Splash Oil Alarm is generated and the request
Engine load reduction is sent (Optional)
- Values from the alarm border the bar graph is red
- If the measured value exceeds the third temperature limit and elapsed a certain time
with 3 seconds, additionally to the previous two alarms "Over Temperature Alarm is
generated and the second request Engine Shutdown is sent
- Values from the max border the bar graph is red
- If the measured value in the range of values, the alarm is deleted
6.17.4 Monitoring Regarding Mean Value Deviation
In addition to the monitoring of the absolute value, the monitoring of the deviation of each
splash oil sensor from the mean value is also necessary to ensure that an overheating of
one sensor over the entire operating temperature range of the engine is recognized.
- If the measured value in the range of value, no alarm is generated
- Values under the pre alarm delta border the bar graph is green
- If the measured value exceeds the first temperature limit and elapsed a certain time
with 3 seconds, the alarm Pre Alarm Mean is generated
- Values from the pre alarm delta border the bar graph is yellow
- If the measured value exceeds the second temperature limit and elapsed a certain time with 3
seconds, additionally the alarm Alarm Mean Sensor is generated and the request Engine
load reduction is sent (Optional)
- Values from the alarm delta border the bar graph is red
- If the measured value exceeds the third temperature limit and elapsed a certain time
with 3 seconds, additionally to the previous two alarms Over Temperature Alarm
Mean Sensor is generated and the second request Automatic Engine Shutdown is
sent.
- Values from the max delta border the bar graph is red
- If the measured value in the range of values, the alarm is deleted
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6.17.5 Wire Break

The temperature sensors are monitored of wire break. If more than half the temperature
sensors have a wire break, then the request Automatic Engine Shutdown is sent.
- If the temperature sensors has a wire break, the alarm Wire Break is generated in
the absolute bar graph and in the mean bar graph
- Value from the absolute bar graph is yellow, shows W/B and the value is 0
- Value from the mean bar graph is yellow, shows N/A and the value is 0
- If the temperature sensors has not a wire break, the alarm Wire Break is deleted

6.17.6 Not Plausible

The temperature sensor is monitored of sharp signal (Optional). If more than half the
temperature sensors are not plausible, then the request Automatic Engine Shutdown is
sent.
- If the value from temperature sensors jump within in a certain time, the alarm Not
Plausible is generated in the absolute bar graph and in the mean bar graph
- Values from the absolute bar graph are yellow, shows N/A and the value is 0
- Values from the mean bar graph are yellow and shows N/A and the value is 0
- If the value from the temperature sensor is constant and the value is nearly the
mean temp, than the alarm Not Plausible is deleted.

6.17.7 Monitoring active
The monitoring is active, when the engine speed greater than 200rpm and elapsed a
certain time with 16 seconds.
The monitoring is not active, when the engine speed less than 30rpm.
6.17.8 TIMER (INTERGRATED)

The program Splash Oil includes TON timer from the IEC.
Therefore, it is necessary to create a multi instance block SFB4.

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6.18 Generator power factor controller

In mains parallel operation, the load factor of the gen. is controlled to a defined reference value.
The control output AVR/PF mode must be set by software push button in position AVR/PF mode.
The following modes are selectable, by software:
Automatic
Manual
Automatic mode:
In idle mode and isolated operation, the generator voltage is controlled by the generator voltage controller.
In mains parallel operation, the load factor is controlled to a definable reference values, adjustable from SCADA
and PC 677B.
The enterable reference value is only permitted in the inductive range. The adjusting of power factor at the gen.
AVR will be done by the outputs AVR Volatge adjust + and AVR Volatge adjust - in panel +GCP.
On the generator voltage controller, in the generator terminal box, the generator voltage is set to a fixed static
value (approx. 4%). 4 %. static means 4% voltage deviation from generator idle mode to generator full load.
Parameter:
Nominal value cos phi
Actual nominal value reactive power
Actual value reactive power
Unit
MVAr
MVAr
Basic setting
12
12
indication
Dead band
Proportional range Xp
Pulse length
Max. pause
MVAr
MVAr
sec
sec
2
5
0.2
5.0
Gradient nominal value

Limitation nominal value by cos phi
Generator active power
Generator reactive power
Generator reactive power max. perm.
Generator apparent power
Generator cos-phi
Final setting
MVAr/s
0,85
MW
MVAr
MVAr
MVA
Indication
Indication
12,65
Indication
Indication
Indication
Indication
Indication
Indication
Manual mode:
In this position is the automatic power factor control out of work. The power can now change by selector
switch item 67S5 Voltage decrease or Voltage increase.
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6.19 Testing of shut down valve X-1SZV1012

Before the engine will start, the ttesting of shut down valve X-1SZV1012 is been done, as follow:
1. . Check of pressure switch 1PSH1012, it has to be activated. If no than comes the fault 111 X1SZV1012 emergency stop valve fault.
2. If item 1 is okay, de-energizing of X-1SZV1012 emergency stop valve
3. The pressure switch 1PSH1012 has to deactivated, if not the fault Fault 111 Engine Shutdown
Circuit Test Not Successful comes.
4. After the test is not okay, the start is blocked.
5. After the test is okay, the test relay will be checked, if it isnt okay the fault 108 Failure Engine
Shutdown Valve Test Relay will appears.
6. After the test is okay, the X-1SZV1012 emergency stop valve is energized and start released.
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6.20 CONTROL OF INTAKE AIR SYSTEM

6.20.1 Charge Air Blow-off System (xxMJQ61BR010/14)
The only active component of the blow-off system is the charge-air blow-off valve (xxMJQ62AA200) with
electrical drive.
Main components
KKS-Code
Reference document
Blow-off valve
xxMJQ62AA200
DRW 11.81031-0067
Blow-off valve feedback open
xxMJQ62CG100
DRW 11.81031-0067
Blow-off valve feedback closed
xxMJQ62CG120
DRW 11.81031-0067
Charge air blow-off valve:
The charge air blow-off valve (xxMJQ62AA200) is controlled by the Plant Control System. The controllable
electrical drive of the valve requires a 4-20 mA signal as command input. For a detailed interface
description please see section Interfaces below and refer to the DEUFRA Manual for the electrical drive of
type LE-10.
The sequence for the control of the valve shall be programmed in the following way:
Open valve after time delay of 10s,
IF
Intake air temperature xxMJQ61CT900 < 5C (hysteresis 1C)
AND
Charge air pressure > 2.3 bar (hysteresis for closing = - 0.3 bar)
OR (if charge air pressure not available)
Filling value > 75 % (hysteresis 5 %)
For malfunction check of charge air blow-off valve see section
Feedback of blow-off valve:

The blow-off valve is equipped with instrumentation for feedback of position OPEN and position CLOSED.
Valve and feedback shall be displayed in SCADA.
Interfaces
For a detailed interface description refer to the DEUFRA manual for the electrical drive of type LE-10.
Power Supply:
Power supply for the valve drive is 24V (DC).
Signals:
OPEN/CLOSED feedback is given as potential free contact.
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Malfunction
Malfunction check of charge air blow-off valve (xxMJQ62AA200):
After opening the charge air blow-off valve, the charge air pressure must decrease by 0.1 bar within
10 seconds, compared to the charge air pressure before opening the valve. Otherwise the charge air blowoff valve has a malfunction.
In case of malfunction of the valve an automatic load reduction of the engine shall be carried out and an
error message shall be displayed.
Alarms
The process control system does not create any alarms from the feedback signals of the blow-off valve.
Remote visualisation is only for indication of temperature.
Start requirements
Not applicable for blow-off system.
Normal operation: manual local

Normal operation: manual remote

Normal operation: automatic remote

Normal operation: automatic local

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Parameters Intake Air System

Code
Description of code
Range:
Value/
Setpoint:
Final
Value:
Input:
xxMJQ61CP900
Differential pressure filter
05.0 mbar
xxMJQ61CT900
Temperature intake air after filter
-50+400 C
xxMJQ62CG100
Feedback blow-off valve OPEN
on / off
xxMJQ62CG120
Feedback blow-off valve CLOSED
on / off
n.a.
Charge air pressure [bar]
n.a.
Engine Filling [%]
0 100 %
n.a.
Engine load [%]
0 100 %
... bar
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
Parameter:
Output:
xxMJQ61CP900
xxMJQ61CP900
xxMJQ61CP900
Alarm high (warning)

Alarm high high (warning + load
reduction)
Alarm low (warning)
on / off
> 4.0 mbar
on / off
> 4.5 mbar
on / off
< 0.3 mbar

AND
engine load
> 60%
Please note, for high flexibility and fine-tuning all values shall be adjustable during commissioning. For later
improvements of the control, all operating cycles shall be logged (number of operating cycle, time and main
parameters) in a table for analysis.
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6.20.2 General intake air instrumentation

The intake air module is equipped with instrumentation to indicate temperature of the intake air and pressure
drop of the filter unit. Additionally, an emergency stop is available for modules that need to be entered for
maintenance.
Main components
Temperature Transmitter
Differential pressure transmitter
Maintenance Switch for engine stop
KKS-Code
xxMJQ61CT900
xxMJQ61CP900
n.a.
Reference document
DRW 11.81031-0067
DRW 11.81031-0067
n.a.
Intake air temperature:

The temperature element (XXMJQ61CT900) is of PT100 type and indicates the temperature of the intake
air after the air filter for the according engine. Connection type of the temperature element is 3-wire circuit.
Its value is shown on SCADA / Panel PC. Furthermore it serves as input for the control of the charge air
temperature control system (CHATCO). See functional description of cooling water system for more
information.
Differential pressure (pocket filter):
The pocket filter unit (xxMJQ61AT012) is equipped with a differential pressure transmitter (xxMJQ61CP900).
It provides an analogue signal (4-20 mA) for indication of the differential pressure of the filter. From this
signal, the plant control system shall create several alarms in order to indicate the condition of the pocket
filters. The alarms are defined in the section below.
Maintenance Switch
The maintenance switch ensures safe conditions during maintenance works inside the module. When
switched, it stops the running engine and/or blocks an engine restart.
Interfaces
For a detailed interface description see wiring diagram.
Power Supply:
Power supply for general instrumentation elements is 24V (DC).
Signals:
Analogue signals are provided as 420 mA signal.
Malfunction
No functional protection against malfunction. Wire-break detection is available.
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Alarms
The signals are transmitted to the plant control system, where they shall be processed in the following way:
Argument definition
KKS-Code
Range
Value
Action
If
diff. pressure
xxMJQ61CP900
< 0.3 mbar
low
show alarm L
AND
engine load
n.a.
> 60%
If
diff. pressure
xxMJQ61CP900
> 4.0 mbar
high
show alarm H
If
diff. pressure
xxMJQ61CP900
> 4.5 mbar
high high
show alarm HH,
load red. to 60 %
The process control system does not create any alarms from the temperature sensor. Remote visualisation
is only for indication of temperature.
Start requirements
Filters must be in position and good condition. Differential pressure must be below Alarm H.
Normal operation: manual local

Not applicable for dry filters.
Normal operation: manual remote

Normal operation: automatic remote

Normal operation: automatic local

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6.21 Princip of auxiliaries Operation modes
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6.21.1 Manual Local Mode Auxiliary Drives
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6.21.2 Manual Remote Mode Auxiliary Drives
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6.21.3 Automatic Remote Mode Auxiliary Drives
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6.21.4 Automatic Local Mode Auxiliary Drives
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6.21.5 Double pumps
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6.21.6 Manual pump switching
6.21.7 Double Starter Pumps, Master Selection Philosophy
Selection of master pump shall be possible in two modes activated for AUTO REMOTE:
1. Master pump selection by operator
2. Master pump selection by operating hours
The operator shall select between the two modes.
Location:
Panel PC at CCP (if selector switch at CCP is in CCP-position)
and from SCADA (if selector switch at CCP is in SCADA-position).
Double starter faceplate with two buttons select Operator Master Selection and Master
Selection by Operating Hours. Selected mode shall be indicated.
General:
THE PUMP WHICH IS RUNNING IS THE MASTER PUMP. IT IS NEVER THE STANDBY
PUMP WHICH IS RUNNING ALONE.
A pump which is disturbed cannot be selected as master.
If one or both pumps are disturbed no selection of mode for master selection or
master is possible.
Operating hours criteria:
Operating hours as the criteria for master shall only be considered for the next AUTO
start of the pumps, not during running pumps.
If pumps are in REMOTE MANUAL, the operator can between selection by operator or
by operating hours if pumps are running or standstill. The operator can change the
master only if both pumps are running or standstill.
Default by PLC Start: Pump 1 is master, master pump selection by operator.
Each selection causes an event.
Description:
Scenario 1:
Pumps standstill and in REMOTE AUTO.
Operator selects Master pump selection by operator (if not already selected)
Operator selects pump 1 as master. If automatic request start of one pump, pump 1 will start.
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or
or
Operator selects pump 2 as master. If automatic request start of one pump, pump 2 will start.
Scenario 2:
Pumps standstill and in REMOTE AUTO.
Operator selects Master pump selection by operating hours (if not already selected)
Pump 1 has less operating hours than pump 2. If automatic request start of one pump, pump
1 will start.
Pump 2 has less operating hours than pump 1. If automatic request start of one pump, pump
2 will start.
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Scenario 3:
or
or
Pump 1 is running in REMOTE AUTO.

Operator selects pump 2 as master. Pump 2 will start and with started pump 2, pump 1
stops.
Operator selects pump 1 as master. Pump 1 will start and with started pump 1, pump 2
stops.
Scenario 4:
Pump 1 failure and stop, master changes to pump 2 and pump 2 shall be started.
Pump 2 failure and stop, master changes to pump 1 and pump 1 shall be started.
Scenario 5:
Pump 1 or 2 is running in REMOTE AUTO.
Operator selects Master pump selection by operating hours (if not already selected)
During running pump mode selection is possible but has no effect on the operation of
pumps.
or
or
or
or
Scenario 6:
Pumps standstill and in REMOTE MANUAL or in LOCAL MANUAL
Selection of the master selection mode and the master pump shall be possible, but has no
influence in REMOTE MANUAL.
Operator starts pump 1. Pump 1 becomes or stays master.
Scenario 7:
Pumps standstill and in REMOTE MANUAL or in LOCAL MANUAL
Pump 1 failure and stop, master changes to pump 2 but no start of pump 2 (no AUTO)
Pump 2 failure and stop, master changes to pump 1 but no start of pump 1 (no AUTO)
Operator starts pump 1 and 2. The first started pump becomes or stays master.
Master selection mode is not effected.
Scenario 8:
Operator selects MANUAL REMOTE and starts pump 2 and stops pump 1.
Pump 2 becomes master.
Operator selects MANUAL REMOTE and starts pump 1 and stops pump 2.
Pump 1 becomes master.
Master selection mode is not effected.
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or
Scenario 9:
Pump 1 is running in REMOTE MANUAL.
Operator selects REMOTE AUTO
Pump 1 keeps master independent from master selection mode (no changeover to lower
operating hours).
Pump 2 is running in REMOTE MANUAL.
Operator selects REMOTE AUTO
Pump 2 keeps master independent from master selection mode (no changeover to lower
operating hours).
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LV ENGINE AUXILIARIES PANEL +EAPX
These panels contain the power components for the motor auxiliaries and the data interface to the
appropriate ECPx panel and stands in the mechanical annex.
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7.1
LV ENGINE Auxiliaries Panel +EAPx frontview
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7.2
Pre lubrication pump 01MJV21AP030-M01 (P007) on MOD006
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
If the motor protective switch is triggered, the oil pump is switched off by the software and hardware. This
switching-off is shown as an error message on the display.
The oil pump has two functions:
1. Start prelubrication
2. Cooling down the engine in case of shut down
The following positions 1-2 are described in the selection switch AUTOMATIC Remote position!
7.2.1
Start prelubrication
Start prelubrication is used to supply the engine with lubricating oil before it is started in order to keep the
mechanical loading of the engine as low as possible Start prelubrication is switched on in the start-up
preconditions. (Start-up preconditions means that the corresponding auxiliary drives for a module start are
activated). A set prelubrication time then follows. After the specified prelubrication time has elapsed and the
system has built up the required prelubrication pressure, the start signal is issued.
Start prelubrication is not necessary, if the standstill time is less than the adjustable time (Max. standstill
time start prelubrication is required).
General:
If an emergency stop is activated or a pump fault, then the pump is switched off by software and hardware.
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Parameter Start prelubrication
Start prelubrication
Max.
standstill
time
start
prelubrication is required
X-1PSH2170 lube oil press.
release Start engine
Hysteresis
Dimension
Basic setting
sec
sec
60
1800
bar
0.3
bar
0.1
see acceptance
certificate
Caution: If the selection switch is in the "OFF" position, prelubrication cannot be carried out, and no start
command is issued.
7.2.2
Cooling down the engine in case of shutdown
In case of shutdown of the engine the oilpump will start for an adjustable time to remove the heat from the
engine.
General:
If an emergency stop is activated or a pump fault, then the pump is switched off by software and hardware.
7.2.3
Parameter: Cooling down function
Idle runtime by shutdown
Dimension
Basic setting
600
see acceptance
certificate
Manaul remote function:

In this position the pump is manual controlled by software push buttons on / off.
Manaul local function:
In this position the pump is manual controlled by hardware push buttons on / off at the switchboard.
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7.3
Generator heating 01MKA01AH010 (H100)
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Automatic function:
The generator heating is released, when the engine is not running
Manaul remote function:
In this position the heating is manual controlled by software push buttons on / off.
General:
If an emergency stop is activated, then the heating is switched off by software.
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7.4
Cylinder Lubrication 01MKA01AH010 (1EM2470)
MANUAL REMOTE
MANUAL LOCAL
7.4.1
AUTOMATIC LOCAL
AUTOMATIC REMOTE
Area of application
To improve the running characteristics, lubricating oil is added to the individual pistons via special boreholes
in the cylinder sleeve.
7.4.2
Vgele System
In the Vgele system, a pump is used to suck lubricating oil from the pressurised engine oil line and feed it to
a block distributor. Through cyclical switching of different oil lines, the block distributor supplies all cylinders.
In Vtype engines, each cylinder bank has a separate system for cylinder lubrication, and both cylinder
lubrication systems are controlled in the same way. One outlet of the block distributor is equipped with a X1FE2470A/B proximity switch that checks the correct functioning (circulation of the block distributor). The
system is considered to be functioning correctly if the signal of the proximity switch changes its switching
status 1FAL2470A/B at least once in the time KSH0010.
The electric motor for cylinder lubrication is protected by a a motor protective switch. If the MCB trips, the
engine control unit receives an overload signal and cylinder lubrication is deactivated, in V-type engines both
the A and B sides are switched off.
There are three possible operating modes:
Manual operation: "Cylinder lubrication ON, for activating cylinder lubrication if the engine stops, for
example to enable lubrication when turning the engine.
Manual operation: "Running in mode, for activation of cylinder lubrication when starting the engine,
for example to start the engine after repair work.
Automatic operation, standard mode, which activates cylinder lubrication from an engine load greater
than X-2GT1022.
The status of cylinder lubrication can be called in the display.
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7.4.3
Process sequence: Cylinder lubrication
Manual operation "Cylinder lubrication ON"
The function can be executed by the operator while the engine is stationary during maintenance work. This
function is automatically deactivated once the time KSH0300 has elapsed. The "Cylinder lubrication ON"
operating mode is not available when the engine is running.
If the function is activated again while it is already running, the time set in KSH0300 is reset and starts again
from the beginning.
If the engine is started while the function is active, the system switches to automatic mode (see section
7.14.6).
Manual operation "Running-in mode"
This function is used to ensure gentle running in of new components following repair, through permanent
lubrication. This function has no time limit and is reset by manually switching off. The "Run-in mode
operating mode can be selected when the engine is stationary and while it is running, but the control unit
does not activate lubrication until the engine is running.
Automatic operation
Automatic operation is the standard operating mode. This mode is always active if neither of the modes
"Cylinder lubrication ON" (only if the engine is running) or "Run-in mode is selected.
In automatic operation, cylinder lubrication is switched on as soon as the engine is running and the load
switching point X-8GSH1022 is exceeded. To prevent constant switching on and off if the engine is running
close to the load switching point, the system takes a hysteresis an delay (KSH0020) into account when
switching off lubrication.
Control response in the event of failure of the input signals
If the lubrication oil pressure signal fails, cylinder lubrication is not activated.
If the engine speed fails, manual operation "Run-in mode and automatic operation are not activated or
deactivated.
The manual operating mode "Cylinder lubrication ON is not affected by a fall in engine speed or an absence
of the engine speed signal.
If the load signal fails, cylinder lubrication is activated when the engine speed X-1SSH1000 is exceeded.
The manual operating modes are not affected by a failure of the load signal.
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Parameter: Cylinder lubrication
The parameters used in the description above (pressures, time monitoring) are shown here as examples:
Parameters
Sample values
KSH0010, Time element monitoring of block distributor circulation

KSH0020, Delay time for automatic cylinder lubrication on/off
KSH0300, Time restriction for manual operation
X-2GT1022, Threshold value of engine load for cylinder lubricator ON
Load hysteresis
X-1SSH1000, Engine speed, engine running
X-1SSL1000, Engine is stationary
X-2PSH2170, Minimum lubrication oil pressure before engine for cylinder
lubricators
10 s
20 s
300 s
50 %
5%
200 U/min
20 U/min
1 bar
Manual local function:

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7.5
Nozzle cooling water module 01MJG34AC010 (MOD005)
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
Automatic Remote function:

The nozzle cooling water module MOD005 is switched on with start conditions and during engine operation.
In case of normal stop of the engine the Nozzle cooling water module will stop too.
If the engine shuts down, the Nozzle cooling water module will stop after the idle run time.
Manual remote function:
In this position the pump is manual controlled by software push buttons on / off.
Generell:
If an emergency stop is activated, then the pump is switched off by software and Hardware.
In this position the pump is manual controlled by hardware push buttons on / off at the switchboard at
MOD005.
7.5.1
Parameters Nozzle cooling water module X0PAB48AC001 (MOD005)
Page: Time parameter

Description of measuring point
Idle runtime by shutdown
Unit
m :s
Set value:
End set value
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7.6
Fuel oil module 01END56AP010 (MOD008), HFO / light fuel oil (LFO)-Operation
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Preselection of the operating mode is made by means of a panel PC situated pushbutton or can be
preselected from SCADA.
On every fuel switchover an appropriate message is issued to point out the actions to be performed on the
fuel system by the operators staff (open and close cooling/heating valves on the fuel module). In addition,
the load is reduced to approx. 70% for approx. 10 minutes to prevent full-load operation with mixed fuel. The
parameters named above can be set.
Diesel operation
The diesel operating mode is used for start-up and as a backup procedure if the HFO conditions are not met.
If the fuel module is switched over to diesel operation from HFO operation, fuel excessive temperature
monitoring (TAH5070) is activated delayed.
If the alarm fuel excessive temperature TAH5070 is displayed for longer than a set time, the genset is shut
down.
HFO operation
Criteria for HFO switch off heavy fuel oil (HFO) operation
Viscosity, if the error message Viscosity high is issued, HFO operation is locked.
By selection of light fuel oil (LFO) operation
If the genset cannot be operated with HFO on account of the criteria mentioned above, the fuel module is
switched over to diesel operation immediately.
The following criteria must be met in order to be able to switch over from diesel oil operation to HFO
operation:
The locking criteria (see above) may not be present.
The HT cooling water temperature must exceed a set value.
The generator circuit breaker must be switched on and the genset must be operated at least with a set
min rating.
Temperature HFO in 3T022
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Steam pressure in 1PTT032
If the criteria above are met, the fuel module is switched over to HFO operation.
During switchover monitoring of the fuel pressure (PAL5070) is deactivated for 3 seconds in order to
suppress the triggering of switchover-related pressure fluctuations.
In HFO operation the monitoring of excessive fuel temperature (TAH5070) is deactivated.
For switchover viscosity monitoring is suppressed for a set time in order to bridge control fluctuations. An
absolute viscosity limit, which is always monitored, is still active.
If the system is shut down on fault from HFO operation, the auxiliary drives which are relevant for HFO
operation are requested constantly and are not shut down after the set idle run time. If, however, the load on
the genset is reduced when it is operational and is deselected, diesel operation is activated as the first
action.

In this position the valves are manual controlled by software push buttons HFO / LFO.
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7.7
HT cooling water preheating module 01MJG31AP020-M01 (P070 on MOD004)
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE

The HT cooling water preheating module is switched on with start preconditions. If engine reached the
ignition speed, the HT cool.water preheating module is stopped.
If the engine stopped, the pump then switched on and runs in idle mode for the set time, so that the engine
can cool down.

In this position the module is manual controlled by software push buttons on / off.
Generell:
If an emergency stop is activated, then the pump is switched off by software and Hardware.
If the engine circuit breaker is triggered, the pump is switched off both in terms of software and hardware.
This is displayed as an error message on the display.

In this position the module is manual controlled by hardware push buttons on / off at the switchboard.
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7.8
Lube oil separator module 01MJV22AT010 (MOD007
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE

The Lube oil separator module is switched on with start conditions and during operation of the engine.
In this position the module is manual controlled by software push buttons on / off.
Generell:
If an emergency stop is activated, then the module is switched off by software and Hardware.
When the failure signal of the lube oil separating unit continuously appears 3 times, or the failure signal of
the Lube oil separating unit lasts 10 Seconds each time the separator will be stopped too.
In this position the module is manual controlled by hardware push buttons on / off at the switchboard.
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7.9
Lubrication oil valve xxMJV23AA202-Y01 on MOD057 (SOV 2303)
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Released operation modes
xxMJV21BB010 =T001
The lubrication oil valve is used to supply fresh oil to the engine.
The levels limits LSH T001 (max.) and LSL T001 (min.), 1LAL T001 (max.max) and 1LAL T001 (min.min)are
formed by the sensor 2PTT001 ore from 1PTT001.
The exceed of the limit value 1LALT001 (min.min) will cause the fault signal lub.oil level low.
The exceed of the limit value 1LALT001 (max.max) will cause the fault signal lub.oil level high, depending of
status of engine.
Operating elements by Software:
Control functions:
Closed
Automatic
Open
Position Automatic operation:
In this position automatic control is carried out, when the filling level 2LSL T001 (min.) is reached, the valve
is opened when the filling level 2LSH T001 (max) is reached the valve is closed. A request is given to the
lubricating oil refill pumps (P012), by opennig signal of valve SOV 2303.
Position Manual operation:
In this position manual control is carried out, by order from software push buttons open / close. A request is
given to the lubricating oil refill pumps (P012), by opennig signal of valve SOV 2303.
Close criteria of xxMJV23AA202-Y01 (SOV2303)

01MJV22CG120 (2GOS1CK2204) of valve 01MJV22 AA200 direction discaharge of three way
valve, between preh.mod. and. lube oil sep. 01MJV22AT010 (MOD007) in discarge pos. fault FE
436 Lube Oil 3-Way Valve Opened In Maintenance Tank Direction appears.
Emergency stop
1LAHH T001 (max.max.) operation/stand still
level 2LSH T001 (max)
WBZT001 Lub. oil service tank wire break -S
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7.9.1
Value Parameter Lubrication oil valve xxMJV23AA202-Y01 (SOV 2303)
T001=xxMJV21BBQ10
Status:
Page : Limit values
Description of measuring point
1LAL T001 (min.min)
Hysteresis
1LAH T001 (max.max.) operation
Hysteresis
1LAH T001 (max.max.) stand still
Hysteresis
2LSL T001 (min.)
Hysteresis
2LSH T001 (max.)
Hysteresis
Unit
mbar
mbar
mbar
mbar
mbar
mbar
mbar
mbar
mbar
mbar
Set value:
End set value:

34
1
52
1
62
1
40
1
44
1
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7.10 Power house ventilator 1 / 2 xxUMF15AN010-M01 / xxUMF15AN010-M02

Due to the heat dissipation from the engine and alternator it is necessary for the corresponding engine
related powerhouse ventilation system to always work simultaneously with the engine. Otherwise the engine,
engine hall and possibly engine related equipment will quickly overheat. This will cause the engine to shut
down and might cause major damage.
Each engine is equipped with two powerhouse inlet ventilation units. Each of the two powerhouse inlet
ventilation units is equipped with pole switchable motors and has 2 stages. Stage 2 uses full RPMs while
stage 1 uses a reduced RPM level. This lowers the volume flow capacity to approx. 2/3.
Each air inlet duct of all powerhouse inlet ventilation units is equipped with two louvers. One for manual
direction adjustments and one motorised for electrical direction adjustment and automatic open/closed
operation.
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
7.10.1 Normal operation automatic remote

In this mode the control system controls the louver motors and fan motors.
The powerhouse inlet ventilation units will be started 5 min before the engine. For this the control system will
open the motorised louvers (01UMF15AA200/210) to allow air flow and activate the ventilation fans
(01UMF15AN011/013). This is necessary to remove any possible flammable gas residues that might have
accumulated inside the powerhouse.
Once the engine stops (regardless of which case) the ventilation system keeps running for another 15 min.
This ensures a proper cooling down phase while the after cooling down pump is in operation. After the
shutdown of the fans the air louvers (01UMF15AA200/210) move into closed position.
The motorised louvers are equipped with two limit switches. These allow a closed and a variable open signal
(to actuate the vertical flow direction).
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Start procedure of powerhouse ventilation system:
Condition definition
KKS-Code
If
Start signal (engine)
xxMJA10AG010
Then
If
Fans signal
xxUMF15AN011/013
And
Air louvers
xxUMF15AA200/210
Then Air louvers
xxUMF15AA200/210
If
Air louver limit switches xxUMF15CG120/180
Then
Then
If
Then
fans
tdelay start engine
Engine
Engine
fans
xxUMF15AN011/013
If
Then
Then
Then
Stop signal (engine)

Engine
fans
tdelay stop fans
Then
Then
Then
Fans
01UMF15AN011/013
Air louvers
01UMF15AA200/210
Air louver limit switches 01UMF15CG100/160
xxMJA10AG010
xxMJA10AG010
xxUMF15AN011/013
xxMJA10AG010
xxMJA10AG010
xxUMF15AN011/013
range
value
action
Yes/No
Yes/No
Open/Closed
Open/Closed
available
available
Yes
Yes
To open
Open
On/Off
0...30min
On (stage 1)
5min
Release start requirement
Start
On (stage 2)
Start/Stop
On/Off
Start/Stop
On/Off
0...30min
15min
On/Off
Open/Closed
Open/Closed
Stop
On (stage 1)
Start
Off
To closed
Closed
With regard to a high availability there shall be also the possibility to receive release start requirement and
operate the engine for short terms if only one of the twin ventilation towers of the engine has the full
functionality for the correct operation. But this operation option should be only used in exceptional cases and
a prompt maintenance of the damaged ventilation unit is necessary. MAN Diesel & Turbo SE does not
recommend engine ventilating with only one ventilation unit and assumes no responsibility if the operator use
this option for continuous operation.
In case of two damaged ventilation units the related engine must not be in operation /must be stopped.
Please pay attention:
- in case of switching down from full speed (stage 2) to low speed (stage 1), a delay of ten (10) seconds
will be needed in order to enable the fan adequately slow down prior to connecting it to lower speed
- in case of switching up from low speed (stage 1) to full speed (stage 2) no delay is needed
7.10.2 Operation manual remote Powerhouse ventilation system

This mode has to be selected at GCP or SCADA. The operator can switch the Ventilation Fans
(01UMF15AN011/13) in manual remote.
When selected the operator can adjust the flow rate of air to the powerhouse as following:
- Switch engine hall ventilation fans to stage 1 or 2
- Switch on/off any number of engine hall ventilation fans
In this way it is possible to avoid overcooling in the powerhouse at low ambient air temperatures. The
symmetrical air flow to the engines has to be maintained.
Operation manual remote is not the recommend control mode of MAN Diesel & Turbo. MAN Diesel & Turbo
assumes no responsibility if the operator use the ventilation units in operation manual remote-mode.
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7.10.3 Operation manual local Powerhouse ventilation system

Operation manual local is not the recommend control mode of MAN Diesel & Turbo. MAN Diesel & Turbo
assumes no responsibility if the operator use the ventilation units in operation manual local-mode.
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7.10.4 Malfunctions
Start conditions:
Argument definition
If
Air louvers
Then
Delay
If
Air louvers
limit switch
Then
Alarm
If
If
Then
Then
Air louvers
Delay
Air louvers l
limit switch
Alarm
Related fan of
faulty air louver
KKS
01UMF15AA200/210
01UMF15CG100/160
range
Open/Closed
0-5 min
Open/Closed
value
2 min
Action
To closed
Start
Not closed (S2 signal)
Initiated in control
system
01UMF15AA200/210
01UMF15CG100/180
Open/Closed
0-5 min
Open/Closed
2 min
To open
Start
Not Open (S3 signal)
system
01UMF15AN011
or
01UMF15AN013
Blocked/Released
KKS
01UMF15CG100/160
or
01UMF15CG120/180
range
Open/Closed
Blocked
During operation
Argument definition
If
Air louvers
limit switch
Then
Alarm
And
Related fan of
faulty air louver
01UMF15AN011
or
01UMF15AN013
value
Action
Not open
system
Off
On/Off
With regard to a high availability there shall be the possibility to operate the engine for short terms if only one
of the twin ventilation towers of the engine has the full functionality for the correct operation. But this
operation option should be only used in exceptional cases and a prompt maintenance of the damaged
ventilation unit is necessary. MAN Diesel & Turbo SE does not recommend engine ventilating with only one
ventilation unit and assumes no responsibility if the operator use this option for continuous operation and
ignore maintenance.
In case of faulty air louvers on both ventilation units the related engine must not be in operation /must be
stopped.
Failure on electrical motors
Argument definition
If
fans
And
If
Then
Fuse of motor
(stage 1)
Concerned
motor
Argument definition
If
fans
KKS
01UMF15AN011
and
01UMF15AN013
01UMF15AN011 M01
or
01UMF15AN013 M01
01UMF15AN011 M01
or
01UMF15AN013 M01
KKS
01UMF15AN011
range
On/Off
value
Action
On (stage 1)
Has tripped
Stage 1 / stage 2
range
On/Off
Switch in stage 2
value
Action
On (stage 2)
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and
01UMF15AN013
And
If
Then
Fuse of motor
(stage 2)
Concerned
motor
01UMF15AN011 M01
or
01UMF15AN013 M01
01UMF15AN011 M01
or
01UMF15AN013 M01
Has tripped
Stage 1 / stage 2
Switch in stage 1
Please pay attention:

- when switching down from full speed (stage 2) to low speed (stage 1), a delay of ten (10) seconds will
be needed in order to enable the fan adequately slow down prior to connecting it to lower speed
- when switching up from low speed (stage 1) to full speed (stage 2) no delay is needed
In case of overheated bearings from electrical motors of the fans (01UMF15AN011/013) the EAP will receive
a signal. Following the EAP will stop the concerned electrical motor automatically.
7.10.5 Alarms
In case of high contamination of the air filters a differential pressure high alarm will be initiated. For this the
powerhouse inlet ventilation units are equipped with differential pressure transmitter.
If
Argument definition
Pressure switches
Then
Pre-Alarm
If
Pressure
Then
Alarm
KKS
01UMF15CP100
or
01UMF15CP200
range
50...500 Pa
value
250
Pa
Action
Above
system
01UMF15CP101
or
01UMF15CP201
50...500 Pa
Above
300
Pa
system
In case of pre-alarm due to high contamination the filter should be changed in the next time (time before the
other differential switch gives alarm). During the filter change procedure ensure that the associated inlet
ventilation unit is not running.
In case of alarm due to high contamination the filter should be changed as soon as possible. With differential
pressures of more than 300 Pa there is no guarantee to get the full required volume flow. During the filter
change procedure ensure that the associated inlet ventilation unit is not running.
In case of an alarm of the fire detection system, the inlet ventilation units have to shut down their
ventilation automatically.
Argument definition
If
Fire alarm
Then Fans
KKS-Code
range
01UMF15AN011/013
Start/Stop
value
action
To stop
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7.11 DO Shut Off Valve Before Booster Module 01EGD53AA202-Y01
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE

In case of fire alarm signal by Profibus-DP from firefighting control panel, it will close.
In this position the valve is manual controlled by software push buttons on / off.
7.12 HFO Shut Off Valve Before Engine 01END56AA202-Y01
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE

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In this position the valve is manual controlled by software push buttons on / off.
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Alfred Kuhse GmbH

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Operating Instruction Genset Control

Operating Instruction Genset Control

Guangopolo II, 5301954

MAN Diesel & TurboSE, Augsburg

Client Order No.:

Alfred Kuhse GmbH

Kuhse Comm. Number :

Rev./ Date / Status

0 / 25.11.2013 / Comm. Edition

Mid voltage level:

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

Purpose ............................................................................................................................................... 10

Functional Descriptions of Operation and Indication Elements ....................... 12

Alfred Kuhse GmbH

Operating Instruction Genset Control

Operating Scenarios ............................................................................................. 47

Overview diagramms ............................................................................................ 55

Engine control functions ...................................................................................... 61

Overall Single line diagram ................................................................................................................. 55

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

Alfred Kuhse GmbH

Operating Instruction Genset Control

Generator power factor controller ........................................................................................................ 96

LV ENGINE Auxiliaries Panel +EAPx ................................................................. 113

Alfred Kuhse GmbH

Operating Instruction Genset Control

Lube oil separator module 01MJV22AT010 (MOD007 ..................................................................... 125

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

461180_Operating Instruction Genset Control Commissioning Edition.doc

Operating Instruction Genset Control

PRINCIPLE FRONT VIEW

2013-07-17 Revision A in work

Operating Instruction Genset Control

2013-07-17 Revision A in work

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

Switches and Push Buttons

Selector Switch Operation Mode GCP/SCADA

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

Selector Switch Alternator Voltage

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH

Operating Instruction Genset Control

Selector Switch Local Synchronization Manual/OFF/Automatic

461180_Operating Instruction Genset Control Commissioning Edition.doc

Alfred Kuhse GmbH