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Structure of Terberg System





Scada
MMI
Application software
Configuration data
Hardware components
Scada
MMI
= Runwin, Editwin, Project Manager
= Screens on the IPC or PC
Application
= Software running in the TEC or SBC
Data
= The configuration data in the TEC or SBC
Hardware
= Boards like Digital Inputs, Outputs, SBC or TEC
Terberg Control Systems
CONT
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U/U
kW
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System setup with SBC
Terberg Control Systems
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Relays
Outputs
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System setup with TEC
Analogue Inputs
Power
Organizer
Analogue
Outputs
LSM
Terberg Control Systems
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Air inlet filter
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TEC
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Contactors for
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Line
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System setup with TEC
This is the
configuration of
the control panel,
mounted in the
C32 container.
Terberg Control Systems
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The TEC
The name TEC stands for TERBERG ENGINE CONTROL.
It is an all together system with enough hardware on board to
control an engine and if required a small piece of CHP.
It is easy to expand with additional IO cards because all CAN
connections are available and can be configured to the most
expanded system configuration required by the application.
On board :
Power Organizer
Digital Inputs
Relays Outputs
Analogue Inputs
Analogue Outputs
Load share lines
PWM output for speed
Terberg Control Systems
RS422/485 converter
Two U/U converters
4-Line LCD
Generator Protections
NEXT
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System setup with TEC
The onboard display has the same functionality as the 4line display, which can be mounted on a door. Most
important values are displayed like power measurement,
analogue input value’s, actual and historical alarms,
synchronizing performance, cylinder temperatures if
applicable.
The button ‘reset alarm’ is available to reset the alarms
that are healthy again.
One can set the amount of power for running ‘hand on
load’ to utility or power mode.
Terberg Control Systems
NEXT
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System setup with TEC
The first two analogue outputs are designed with U/U
cards which provide isolation and voltage range of -10 to
+ 10 Volts DC. When the current option is selected, it
acts as a normal 0-20 mA output. These two outputs are
designed for the speed and voltage control but in case of
a GECM with PWM speed adjusted input, the channel 0
will be used for the required kW feedback signal to the
GECM for the AIR/FUEL ratio control. With a current
speed adjustable input, the output 2 will be used for the
speed and channel 0 for the kW feedback.
Channel 2 and 3 are normal common analogue outputs
with a 0 – 10 Volts DC range or 0 – 20 mA.
Terberg Control Systems
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System setup with TEC
8 analogue inputs are available on board. Standard these
inputs can measure voltage in the range of 0 – 10 Volt
DC. With the selector switch in mA position, the current
input range will be 0 – 20 mA. The current inputs are
designed for active components.
When a small converter card is placed like the PT100,
Thermocouple or 0-35 Vdc, the switch need to be in
voltage position.
Terberg Control Systems
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System setup with TEC
16 digital inputs which are more than required to run an
C32 engine without extra IO cards regarding engine
protections and control.
The first 4 inputs can be configured to perform as a NPN
input. This means that the input needs to be grounded to
toggle the input. Example of such input is the Oil level
low switch mounted on the engine.
Terberg Control Systems
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System setup with TEC
16 relay outputs are available to control the engine and
generator breaker. The first 4 relays are designed for
higher currents for generator synchronizer breaker and
fuel valve control. The other relays are free configurable
to control the engine or other devices.
Note: Only normal open contacts are available.
Terberg Control Systems
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System setup with TEC
Special IO:
Speed Control PWM output, this output is used on C32
engine control. PWM = Pulse With Modulation.
Pickup input, to be used on A-type engines for
determine engine running and over speed protection.
Hardware loadshare line output connection.
Synchronizer Pulse, not used.
Outputs indicating mains and generator voltage failure.
Future Earth Fault detection input.
Terberg Control Systems
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System setup with TEC
In this area the 2 serial communication ports are
located. COM 0 is the com port which needs to be
used to upload application software. COM 1 can
be used to monitor the process like on COM 0
except programming. To up- or download data
configuration or text files for LCD, both ports can
be used.
The reset button is located just above the two
dipswitches. These dipswitches are to enable the
reset button and to activate the download
program. In normal conditions, both dipswitches
should be switched in OFF position!
The RJ45 Ethernet connection will be used in the
future. Now it is unused.
The small relay in the right top corner of the
picture is the watchdog relay. When the TEC is
healthy and running, the relay is energized.
Terberg Control Systems
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System setup with TEC
6 LED’s are indicating the status of the TEC.
Power LED, indicating 24 Volt DC is
available.
Run LED, indicating the application is
running.
Low Battery, indicating that the internal
battery is getting low in voltage. Risk is
present to lose data when 24 Volt fails.
CAN 1, when blinking indicating that the
network is healthy and running.
CAN 2, when blinking indicating that the
network is healthy and running.
CAN 3, when blinking indicating that the
network is healthy and running.
The serial number of the TEC will be visible here.
Terberg Control Systems
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Extending I/O cards
In addition to the basic system configuration, extra IO is required
for:
Touch screen:
CHP application:
Modbus:
EMCP3:
Terberg Control Systems
additional DI16 and DO16.
additional cards are required to control
3-way valves, fans, pump systems.
SBC-COM or CAN-COM module.
SBC-COM.
NEXT
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The CAN network system
The way of communication between the devices
we have is done by a well proven CAN network.
There are three networks available :
 IO CAN (network 1)
 CPU CAN (network 2)
 MASTER CAN (network 3)
Terberg Control Systems
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The CAN network system
IO CAN
= communication between the IO cards
like digital input/output cards, analogue
input/output cards, relay cards, LSM.
CPU CAN
= communication between the Interface
cards, Power Organizer and LCD.
MASTER CAN
= communication between different
SBC’s or TEC’s to have a multiple
engine configuration with or
without a master.
Terberg Control Systems
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The CAN network system
Can 1 and 2 are configured as a slave network. This means that
the SBC or TEC is requesting specific data from IO cards and
that these messages have a unique ID. The response time of the
IO cards should be low otherwise failure will be initiated.
Can 3 is a multi master network. The
messages are basically broadcast
messages. No feedback is required.
Terberg Control Systems
NEXT
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The CAN network system
Each network device should be connected
according to a ‘DAISY CHAIN’ network. This means
that no STAR point connections are allowed. The
beginning and the end of the network should be
terminated by a 120 ohm resistor. This resistor is
available in the terminator plug.
Terberg Control Systems
NEXT
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The CAN network system
All CAN devices need to have a dedicated address. In each
message send from the master an ID will be included. The device
with the matching address will respond to the message with his
ID. This address is set with the CAN address rotary switch.
When using a multiple engine
configuration, all C32 engines can be
connected to each other by CAN 3
connection. The first and last engine
should have the previous mentioned
terminator plug installed and the other
engines are connected with the prefabricated purple CAN cable with
connectors.
Terberg Control Systems
NEXT
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Engine number configuration
Each engine needs to have an unique ID (engine number) that can be provided
with the CAN address rotary switch on the TEC or SBC.
Terberg Control Systems
Engine 1
Engine 6
Engine 2
Engine 7
Engine 3
Engine 8
Engine 4
Engine 9
Engine 5
Engine 10
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Load sharing with C32
C32 engine control is designed to use the CAN 3 network for load sharing. But
with a minor change it is also possible to use the hardware load share mode.
The control is compatible with the Woodward Loadsharing Module.
When to use CAN 3 load sharing:
default application with other C32 and TCS controls.
running to utility with import/export control.
When to use hardware load share lines:
if other engine is not TCS control.
Advantage CAN 3:
kW and kVar sharing
import/export control
pre-alarm intervention
control by master system possible
Terberg Control Systems
Advantage Load share lines:
load sharing with non-Terberg controls
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HMI (Human Machine Interface)
To provide the operator with information about the system, an interface is
required. The control systems can be provided with:
4-Line display
TOP (Terberg Operating Panel) touch screen
 IPC (Industrial Personal Computer).
Laptop.
Remote monitoring.
Terberg Control Systems
NEXT
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HMI (Human Machine Interface)
The LCD is just an information interface. No settings can be changed
except the amount of load required in HAND ON LOAD position and
running on utility and power mode.
The TOP 5.7 will give more detailed information and is better in fault
analysis. Reduced parameter settings are available.
IPC will show all available data. Setup of the system is possible and data
logging, multiple graphs are available.
Laptop will have the same options as the IPC. Advisable at commissioning
jobs.
Remote monitoring is depending on the option that is required.
Terberg Control Systems
NEXT
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HMI (Human Machine Interface)
Remote Monitoring:
Default method is connecting the remote monitoring
computer via Intranet (RJ45) to the TOP.
For the TOP V1.0, an USB/Ethernet converter is required.
Ethernet option is available on the TOP V1.1
On a system without the TOP screens, the RS485 network option is
available.
Modbus/BMS connection. This is limited in the amount of
data available.
Terberg Control Systems
NEXT
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HMI (Human Machine Interface)
Connections required for the HMI types:
LCD:
CAN 1 and CAN 2
TOP 5.7:
RS232 and CAN 1
IPC:
RS232 and CAN 1
REMOTE MONITOR:
ETHERNET
RS485/422
RS232
Terberg Control Systems
NEXT
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Software installation
Minimal requirements for running the Terberg Control System
software are:
Dongle driver
Dongle key with license
Terberg IDE
Runwin
Serial port (hardware or USB to Serial converter)
RS232 serial communication cable with 3 cores on pin 2, 3 and 5.
Pin 2 and 3 should be crossed.
Windows 2000 or later.
Terberg Control Systems
NEXT
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Software installation
The software is protected by the Dongle and needs to be installed as soon as
one of the Terberg software packages needs to be run. This will protect
illegal operation of other possible dealers in the same area. It also is a
license to use the software and is valid for 1 year (Service Engineer Dongle).
Terberg IDE is the software application which is used for selecting the project,
fault finding, communication test, backing up system, copying data from one
to an other system and re-flashing the TEC/SBC.
Runwin is the application that melts the database requested information
together with the screens. It shows the screen and gathers the information
from the TEC/SBC and project this on the selected screen.
Optional programs are:
- Editwin, to configure the screens with desired data.
- Project manager, to select projects on a remote monitoring PC.
- License manager, to re-fresh the license of the dongle after expiration.
Terberg Control Systems
NEXT
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Note: The disk on the TOP 5.7” is named : FFDISK
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Software installation
Structure on the hard disk:
C:\IAR
(optional compiler).
C:\SBC\CAT_GENEVA\C32\TEC.V1\MMI (HMI files)
C:\SBC\CAT_GENEVA\C32\TEC.V1\SBC (Project files)
..\MMI\Def
(Definition files)
..\MMI\Edit
(Text files, Definition of project screens)
..\MMI\Pict
(Project picture screens)
..\SBC\Data
(Data configuration files)
..\SBC\Next
(Intel hex file, Source files)
..\SBC\Sys
(Terberg IDE database files)
Terberg Control Systems
NEXT
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Software installation
..\MMI\Edit
(Text files, Definition of project screens)
Within this directory, a few interesting files are located.
Analoog.bim
– Contains the names of all analogue in- output channels.
Input.bim
– Contains the names of all digital inputs.
Output.bim
– Contains the names of all digital outputs.
Storing.bim
– Contains all the alarm descriptions.
Masters.phn
– Contains the project name, displayed on the right bottom side.
Pages_ex.prj
– Contains the project pictures configuration
..\MMI\Pict
(Project picture screens)
This directory contains the pictures of the project but might also have the file:
mg_def.bim – It contains the motor group definition names.
All these files can be edited by a normal text editor like write or notepad. After a
restart of RUNWIN, the new text should be visible.
Terberg Control Systems
NEXT
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First start-up of Scada
To check that the software license dongle is recognized and having a valid
license, we should be able to test this with the Terberg IDE program.
Plug in the USB software dongle in an available USB port.
Wait until the software has been installed for this device.
Start Terberg IDE and monitor the Terberg Welcome screen. It should tell
you the expiration date.
No DEMO mode should be visible.
Selecting a project. The path to the project is C:\SBC\CAT_GENEVA\C32.V31\TEC.V1
Confirm after selection the project path at the top of the Terberg IDE window.
If no RS232 port is available, one can use an USB to serial converter. Install in that case
the converter and select options to verify the selected com port. Connect the serial
cable from the com port to the TEC/SBC com0 port. Open the watch list and verify
the communications with the TEC/SBC. Note: There should be variables in the watch
list otherwise no communication will be started. If empty, insert S17 (Aux timer).
Terberg Control Systems
NEXT
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First start-up of Scada
When the communication with the TEC/SBC has been proven, we should be able to start
the RUNWIN program to monitor the performance by the project screens.
Select the RUNSIM icon (or via ‘Configuration’ the RUNWIN command).
After the splash screen
of Runwin, a separate
icon should appear at
the right bottom side
nearby the clock. This
icon represents the
SBCserver program.
Double click on the
icon to open the
SBCserver window.
Verify that the serial
block is tagged. Check
that the ‘Use Sx and
Use Nx’ are not
tagged. ‘Autobaud
enabled’ should be
tagged.
Terberg Control Systems
NEXT
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Fault finding communications
Fault finding serial communication:
If the communication is not working, possible errors could be:
The serial com port has been blocked by other program (like CDVR).
SBCserver still running after quitting Runwin. Terberg IDE will not find free
com port.
Terberg IDE has been started twice. This will result in an off-line IDE.
Com port configuration has not been saved after laptop shutdown.
Tag serial in SBCserver has been switched off when running Runwin without
dongle.
Enable autobaud has been disabled. Selected baudrate differs from that on
the TEC/SBC.
Wrong cable is used. The correct cable is a three core cable with pins 2 and
3 crossed and pin 5 to pin 5 connected. Two female sub 9-D connectors are
used.
Terberg Control Systems
NEXT
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Note
:
Fuse
is
located
at
220
Vac
entrance
plug!
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Getting started with training kit
Open the box and take out the power cord, the
serial communication and the CAN cable.
Connect the power cord to the mains with the
plug provided or when the wall plug is
different, use your local power cord. The
supply voltage should be between 100 – 240
VAC 50/60 Hz.
After switching on the supply, the TEC should
start-up including the TOP screen.
Connect the serial cable to COM0 and your
laptop COM port.
Do not use the CAN cable until instructed.
Terberg Control Systems
NEXT
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Getting started with training kit
Power Plug
CAN 3
Temperature
simulations
Protection
Inputs
TEC
Speed and Voltage control out
Serial COM port
Terberg Control Systems
NEXT
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Getting started with training kit
USB port.
This port is used to
update the screens
on the TOP.
Top 5.7 “
Key switch with start/stop control
Terberg Control Systems
NEXT
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Getting started with training kit
These potentiometers are used to simulate the
temperatures as labeled.
It is possible to test the setpoint alarms and trips
when the engine is running or stopped and you want
to start.
Terberg Control Systems
NEXT
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Getting started with training kit
The most important
analogue outputs to
control an engine are
the speed and
voltage adjust
outputs.
On the trainings kit,
both outputs are
connected to a
voltage meter to
show the effect when
running the engine
in Island or Parallel.
Terberg Control Systems
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Getting started with training kit
These connections are used in multiple
engine configuration. The first engine needs
to have the terminator plug installed on the
‘previous engine’ and the second engine on
the ‘next engine’ connector.
Terberg Control Systems
The last
engine will
have the
previous
engine
connected to
the same
labeled
connector.
The
terminator
plug needs to
be installed
on the ‘next
engine’
connector.
NEXT
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Getting started with training kit
The switches on the top of the TEC are to simulate engine trip contacts.
The USB port besides the TOP 5.7 “ is connected to the
TOP screen and can be used to update pictures or
retrieving screen dumps.
Terberg Control Systems
NEXT
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Touch panel buttons
Each control panel with TOP 5”7 is provided with control buttons. The IPC will be shipped
from May 2008 with the same buttons available.
From the left, the ‘enable speed manual’ will force the speed control in manual and with
the buttons raise and lower, one can change the speed of the engine. Release the ‘enable
speed manual’ will disable the raise and lower buttons and activate the PID control.
The ‘enable voltage manual’ will do the same as the speed option, except this will effect
the voltage control.
With the ‘engine start’ button, the engine will be released and start.
To stop an engine running, the ‘engine stop’ button will issue a stop command. When
running on load, the engine will unload itself before it opens the breaker and enters the
cool down step.
The key switch will switch the mode of operation. Automatic and Hand Load will close
the engine to the bus. Hand off load is a test mode.
Terberg Control Systems
NEXT
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Touch panel buttons
The buttons shown on the IPC have the same functionality
as the hardware buttons described on the previous page.
The only difference is that the key switch function can be
disabled by the ‘Enable control buttons’. As soon this
button is pressed, the mode of operation box will be
highlighted by the color green. From that moment, the
mode of operation can be changed by HMI.
The hardware key switch will allow the mode change
without the control buttons enabled.
The ‘AUTO’ mode will start the engine
automatically when a load request is available
or when the engine needs to start in
emergency power mode.
In the ‘OFF’ position, nothing is activated.
In ‘HAND OFF LOAD’, the engine starts when
the RELEASE button is pressed and no alarms
active. The breaker will NOT be closed.
In ‘HAND ON LOAD’, the engine will perform as
in ‘HAND OFF LOAD’ except it will close the
breaker and runs at pre-defined load.
Terberg Control Systems
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TOP screens
This is the first screen on the TOP. It allows you to
enter a higher level password to change
parameters on the TOP.
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TOP screens
The TREE is a quick reference of all the available
screens. It lets you select the required screen
without pressing on the next page all the time.
Terberg Control Systems
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TOP screens
The actual alarm list
shows you which
alarm did cause the
engine to stop. It
also shows you all
the active events. An
indicator will
differentiate
between an
emergency stop or a
normal stop. Also
status events can be
seen.
Terberg Control Systems
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TOP screens
Historical alarm list
gives the events that
happened in the past.
The time in minutes
and date is stored for
each event. A red
rising sign indicates
the time an event
happened and the
green falling sign
shows the time the
event is cleared.
The events shown in the list are starting with a number and
than the description. This alarm number is important if you
need support from CATERPILLAR/TERBERG. In case of
problems, please note the alarm number and description!
Terberg Control Systems
NEXT
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TOP screens
The alarm details
show the actions that
will be taken when
the event is activated.
Question:
Does the alarm
‘Exhaust temp
high’ stop the
engine
immediately ?
In this example, alarm 68 is triggered when the exhaust temp is high and according to this
configuration it will not auto reset itself, shows up in the actual and historical alarm list. It
will activate the optional connected alarm lamp and will be active also in island operation.
When a modem is connected to the TEC/SBC, it will call the base station.
Terberg Control Systems
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TOP screens
The small breaker
inside the
alternator shows
the engine’s online status.
The engine overview shows the produced power,
winding temperatures of the alternator, exhaust
and ambient temperatures.
Terberg Control Systems
NEXT
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TOP screens
The synchroscope shows the synchronization
process. The manual speed and voltage control
buttons are available too.
Terberg Control Systems
NEXT
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TOP screens
The power
organiser page
shows the busbar
voltage. It shows
the produced
power and related
measurements.
The phase
sequence of the
bus and generator
can be monitored.
During
synchronization, a
bar will display the
synchronization
process.
Terberg Control Systems
NEXT
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TOP screens
The load control
page is used for
parallel operation.
On the left the load
demand for auto and
hand on load are
defined. In the
centre part, derating of power can
be activated when
the engine starts to
overheat. The ramp
rate is pre-adjusted
to have a smooth
operation when
increasing or
decreasing the load
demand.
Below the load demand configuration, brief information is shown when the engine
is operating in island mode. On the most right side, the actual load is shown in
percentage to the rated power (in this example 800 kW).
Terberg Control Systems
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TOP screens
The process
variables page is
used to configure the
system according to
application
requirements. These
settings have been
adjusted at the
factory and except of
the operation mode
and number of
engines, no other
adjustments should
be necessary in the
field.
In multiple engine applications, one needs to adjust the ‘Number of engines’
according to the, by CAN 3, connected number of engines. This should be
done on engine 1. Also the ‘Operation mode’ needs to be set. For most rental
applications this will be ‘Always run in Island’.
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TOP screens
When running in Island with multiple engines
connected by CAN, the starting and stopping of
engines is depending on the load is defined here.
Terberg Control Systems
NEXT
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TOP screens
These screens will show all the connected engines and there produced power, frequency
and power factor. This quick overview will help you to correct some imbalance in pF or
kW control if existing.
Terberg Control Systems
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TOP screens
Because all
communication
with IO devices is
done by CAN
networks, it is
important that
these networks
are healthy and
running. This can
be verified on the
CAN
PERFORMANCE
page.
IMPORTANT information is shown on the top of this screen. It
shows the Operating System and more important, the
Application version. This will be asked when having
questions about operating problems.
Terberg Control Systems
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TOP screens
The Digital Input page shows all the configured inputs on the system
and the current status. An inversed input will be indicated with the text
‘inversed’. The software will see the opposite of the hardware input
level.
Terberg Control Systems
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TOP screens
The Digital Output screen shows all the configured
outputs on the system. On the left LED, one can
see if the output is activated (closed).
Terberg Control Systems
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TOP screens
The Analogue Input screen will show the
configured analogue inputs and there raw value.
No decimal point is presented here.
Terberg Control Systems
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TOP screens
The setpoints are
used to protect
the engine on
temperatures.
When the
configured
temperature
reaches a
setpoint, the
related alarm will
be triggered.
For each analogue channel, a maximum of 4
setpoints can be available. This is defined in the
software code and can not be changed in the field.
Terberg Control Systems
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TOP screens
The
Analogue
Output
screen
shows you
the voltage
that should
be
available
on the
outputs.
The first
two
channels
on the TEC
have a
range of 10 to +10
volts.
Terberg Control Systems
The output voltage on AO0.1 will be ?
1,5
0,8
-0,7
-3.0
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Program Sequence
To run an engine, several steps needs to be taken before and
during running. At the same time alarm conditions are monitored
and action should be taken if required on an event.
There are basically two programs running at the
same time:
1.
2.
Start sequence.
Alarm program.
Terberg Control Systems
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Program Sequence
211 Engine wait for reset
011 Wait for start
041 Ventilation engine room
061 Engine purge cycle
071 Engine start cycle
081 Engine to rated
091 Engine stabilization
101 Engine warming up
111 Start up protection
if voltage available
131 Voltage matching
141 Synchronization
else
mode ‘off load’?
211 Running of load
else
121 Close generator breaker (dead bus)
151 NORMAL OPERATION
Terberg Control Systems
Event has happened!
Action code of alarm is retrieved.
Event displayed in actual alarm list.
Event stored in historical alarm list.
If action is:
A-fault, breaker open and engine direct
stop.
D-fault, breaker open and engine in
cool down.
B-fault, engine unloading, breaker open
and cool down.
Normal stop, engine unloading, breaker
open and cool down. Engine will start
when load request is available again.
NEXT
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I/O Configuration
The engine application software has standard a database build in with all
forthcoming IO points. This database is build during our experience with the
engine market. The database is used to couple a hardware in- or output to the
correct software function. This is done by the so called couple numbers.
To change the configuration of in- and/or outputs, one can use these screens.
No software upload needs to be done. It is advisable to make the changes when
the engine is not running.
Terberg Control Systems
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Analogue setpoints
At most engine applications there are temperatures that needs to be measured
and displayed. Not only important information for the operator, but also to have
the control system protecting the engine from overheating. This last function is
performed less and less by the TCS panel due to the GECM-ITSM and EMCP
functions.
Still there are temperatures that are not monitored by these systems and needs
to be protected by the control panel. These temperatures are for example the
STATOR WINDINGS and BEARING temperatures if applicable.
For each analogue input that is
configured for protection there will
be at least one setpoint which is
coupled to an alarm. Depending on
the level and configuration of the
alarm, the engine will stop directly
or unload and cools down.
Terberg Control Systems
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I/O Forcing
The system is able to force inputs and outputs for testing and temporary
purposes. This can be done by the RUNWIN HMI screens.
Note : When forcing outputs, special care needs to
be taken!
Special attention is required by:
Couple 10 (Allow to close)
Couple 57 (Close command)
Couple 9 (Open command)
or
Couple 4 (Engine run)
Couple 20 (Engine start)
Terberg Control Systems
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I/O performance
With the option to change and
configure the engine control panels by
HMI screens, it is easy to make an
error in the configuration.
One of the mistakes could be that one
of the new added inputs is already
configured in the system. This will
result in changing status levels, on for
instance digital inputs. The processor
will receive from both different input
cards possible a low and a high
condition.
To warn the user, there is a warning
indication on the input pages that will
tell you when an input already exist.
Terberg Control Systems
For outputs, there is no critical
situation. A warning is available but
it will not effect the overall
performance!
NEXT
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Maintenance on TCS
Maintenance on the C32 TCS control
panel is limited to the air filters on a
frequent base.
The inside panel batteries do have a
minimum live time of 5 years. After
this it is strongly advised to replace
them.
Terberg Control Systems
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Close loop systems
Terberg Control Systems
NEXT
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1.
Set
of
PID
parameters
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2
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that are used when the
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engine is running in
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Island
mode.
3
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2.
PID parameters that are
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used
when
running
OFF
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4
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LOAD
or
during
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Synchronization.
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3.
Selection
to
have
the
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PID setting copied from
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5
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the master (or engine 1)
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1
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or when switched to
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6
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LOCAL, one can have
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different PID settings for
7
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this engine. Default in
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multiple engine
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configuration,
the
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setting is MASTER.
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4.
After
each
change
on
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.
the
kp,
Ki,
Kd
or
Time
.
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.
8
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.
Base, the PID controller
.
.
.
.
.
. change when the PID control
5.
These
parameters
affecting
the
speed
of
.
.
.
needs
to
be
initialized
to
.
.
.
.
.
.SPEED MANUAL or ENABLE
is switched to MANUAL mode (ENABLE
.
.
.
restart
calculations
.
.
.
.
.
.The higher the number, the
VOLTAGE
MANUAL
on
the
front
panel).
.
.
.
with
the
new
.
.
.
.
.
.
faster
the
PID
output
will
change.
.
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.
parameters.
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6.
Selection of the output type. Choice
is Analogue
or PWM.
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7.
The rated frequency of the system.
This. can be adjusted from 45.00 to
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.
65.00
Hz.
.
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.
8.
The
actual
frequency
of
the
generator,
measured
by the internal Power
.
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.
Organizer.
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.........................................................................................................................................
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NEXT
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Advanced PID control
Terberg Control Systems
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9
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10
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11
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12
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13
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14
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15
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16
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9.
The setting of the first level that will introduce a dead band.
If the
.
.
. error of the ID control
.
.
.
.
.
.
is
lower
than
level
1,
the
PID
will
not
change
its
output.
When
the
.
.
. error is above the
.
.
.
.
.
.
level,
it
will
start
changing
the
output
with
the
parameters
1.
.
. at BAND
.
.
.
.
.
.
.
10. If the error is passing the level 2, the second set of PID (BAND
2).. will be used. This set
.
.
.
.
.
.
.
is
normally
more
aggressive
then
the
BAND
1.
.
.
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.
.
11. Differential around the set point, this prevents continuously
switching
between the 2 set
.
.
.
.
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.
.
.
of settings when the input difference is on the switch over.. point. ..
.
.
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.
.
12.
With the Time Base the calculations of the control are affected.
The
faster the time, the
.
.
.
.
.
.
.
.
.
more aggressive the control will be.
.
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.
13.
LED
indicators
shoeing
which
band
is
used
at
current
situation.
.
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.
14. kP is the gain value of the PID control. A higher number will
result
.
.
. in more gain.
.
.
.
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.
.
15.
kI
is
the
integral
function.
This
parameter
takes
care
of
the
left
over
error when the gain
.
.
.
.
.
.
.
.
.
adjusted
the
output
after
a
input
change.
.
.
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.
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.
.
.
16.
kD
is
the
derivative
function.
It
kicks
the
output
for
a
short
moment,
depending on the
.
.
.
.
.
.
.
.
.
Time
Base
and
kD
value.
.
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.........................................................................................................................................
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Advanced PID control
Terberg Control Systems
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The PID settings are copied from the MASTER or ENGINE 1. Following
.
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.
. to be .
screen
is
the
screen
where
changes
regarding
the
settings
needs
.
.
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.
.
made
when
the
CONTROL
MODE
(callout
3)
is
selected
MASTER.
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.........................................................................................................................................
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Advanced PID control
Terberg Control Systems
NEXT
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.........................................................................................................................................
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The
voltage
. control
. is used to maintain the
.
.
.
.
.
.
.
rated
voltage
.
setpoint
.
when the engine is
.
.
.
.
.
.
.
running in Island
.
or
. Off Load.
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Advanced PID control
Terberg Control Systems
NEXT
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18
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17 .
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For detailed information see the frequency control.
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17.
Setpoint
for
the
desired
pF
value
when
running
parallel
to
utility.
The
.
.
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.
.
setpoint in Island is the average calculated pF of the busbar.. load. ..
.
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.
.
.to
18. This set of PID settings is used when the engine is running parallel
.
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utility. This mode might be forced by the process variables or
.
. received
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.
from the mains incomer status.
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.........................................................................................................................................
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Advanced PID control
Terberg Control Systems
NEXT
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The
load
control
is
one
of
the
most
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.
important PID controls. This
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.
controller
is
used
always
when
the
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.
engine
is
on-line.
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Advanced PID control
Terberg Control Systems
NEXT
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PID behaviour adjustments
When a single engine is instable during off load or on load
conditions, it is important to determine if the engine is instable or
the PID settings are to wild. This can be done by switching the
speed control in manual mode. When the engine is stable, a
correction of the PID settings might be required. But before we
start adjusting, it is important to monitor the analogue output
boundary settings. With the C32 and the PWM output, the
boundary on the analogue speed control are very important
because the GECM is not limited on the PWM input. With the full
range of the PWM signal, the speed can vary from very low RPM to
very HIGH. This means that a small change in signal, the effect will
be big in speed.
Advise: Check the output boundary on the speed analogue output
by manual lowering and increasing the speed. Min speed should be
1475 and high speed 1575. If these limits are bigger, output
boundaries should be corrected before PID settings are going to be
changed.
Terberg Control Systems
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Some
characteristics
for
P,
I
and
D
.
.
.
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.
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.
.
System behavior is depending on the
.
.
.
.
.
.
amounts,
K
values,
for
P
I
and
D.
.
.
.
.........................................................................................................................................
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.
In diagram 1 the value for kD and or kP
.
.
.
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.
is too high, resulting in an unstable
.
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.
.
erratic behavior. The value kP is
.
.
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.
responsible for the amplitude of the
.
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.
signal while kD is responsible for the
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slopes, sinusoid form of the signal.
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The
response
in
diagram
2
might
be
.
.
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.
.
improved by increasing the value for kD
.
.
.
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.
to
increase
the
slope
of
the
signal,
thus
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.
a faster response.
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The overshoot in diagram 3 can be
.
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.
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.
reduced
by
increasing
kD
and
reducing
.
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.
kP.
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The setting time in diagram 4 might be
.
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.
.
reduced
by
increasing
kD
and
reducing
.
.
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.
kI.
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.
.
Diagram
5
shows
the
effect
of
a
too
low
.
.
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.
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.
.
.
.
I, creating an asymptotic behavior for P.
.
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.
Finnally diagram 6 shows an almost
.
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.
.
perfect behavior, fast rise time, no
.
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.
.
overshoot and a smooth signal reaching
.
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.
the setpoint.
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.........................................................................................................................................
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PID behaviour adjustments
Terberg Control Systems
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LSM control
Terberg Control Systems
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Set-up
loadshare
module:
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1)
Start engine off load, and make sure that the frequency setpoint
is set.. to rated busbar
.
.
.
.
.
frequency (50.00 or 60.00 Hz)
.
.
.
.........................................................................................................................................
.
. set-up .this is not
2)
Press button preset speed reference (only required once. After
.
.
.
.
.
.
.
.value manually
.
required
any
more)
(if
it
is
not
acknowledged,
copy
start-up
via the
.
.
.
.
.
.
screen)
.
.
.
.
.
.
.
. signal will be
3)
Synchronise the circuit breaker and start load sharing. (Speed.. reference
.
.
.
.
.
.
.
. is reinstated
set
after
closing
the
generator
circuit
breaker.
Because
the
rated
speed
.
.
.
.
.
.not distort the
after
closing
the
generator
circuit
breaker,
active
synchronisation
will
.
.
.
.
.
.
.
.
.
rated
speed
signal)
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. the average of
After
closing
of
synchronising
breaker
and
the
load
has
become
stable,
.
.
.
.
.
. be adjusted.
the
output
kW
control
signal
should
be
0.
If
not,
the
rated
speed
must
.
.
.
.
.
.
.
.
.
Realise
that,
while
the
speed
control
is
in
manual,
the
load
sharing
is
not
controlled,
.
.
.
.
.
.
and
engine
load
could
drift
away.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
If the balance between the engines needs to be changed, one.. needs to.. adjust actual
.
.
.
.
.
.
.
gain. The test signal will give 6.00V if engine is running at 100.0%
load
.
.
.
.
.
.
.
. it will be
. enough only to
If
the
response
from
on
the
requested
engine
load
is
too
slow,
.
.
.
.
.
.
increase kI (because speed control is in isochronous, pid settings
are different
on pid
.
.
.
.
.
.
.
.
.
sharing).
If
there
is
a
slow
load
imbalance
between
the
engines,
one
has
to
reduce
the
.
.
.
.
.
.
KI
factor
to
stabilise.
.
.
.
.
.
.
.
. Performance
.
One may reset both Kp and Kd to 0 if loadshare lines are used.
might be
.
.
.
.
.
.
.
. compare,
.
improved
if
Kp
and
Kd
are
used,
but
it
will
behave
without.
(To
a
Woodward
.
.
.
.
loadshare module has a fixed I action, no Kp and no Kd, only ..the gain ..can be
.
.
.
.
.
.
.
adjusted).
.
.
.
.
.
.
.
. control too
.
It
is
recommended
not
to
try
to
make
the
response
of
the
kW
quick. If the
.
.
.
.
.
.
settings
are
too
high,
the
busbar
frequency
may
become
slightly
instable.
Realise the
.
.
.
.
.
.
.
. the speed
.
output
of
the
loadshare
module
will
change
the
rated
speed
of
control
unit,
.
.
.
.
.
.
running
in
isochronous
mode.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.........................................................................................................................................
.
.
.
.
.
.
LSM control
Terberg Control Systems
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PID controls in different modes
For running the engine controlled in every mode of operation, we have 4 different PID
controls as shown before.
These controls are switched on when :
Island
LSM
Island
CAN 3
Isolated
Island
Voltage control
X
X
Frequency control
X
X
Power factor control
Load control
Terberg Control Systems
X
Parallel to
Mains
Island LSM
and CAN 3
X
X
X
X
X
X
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Synchronization test
Before you decide to run engines parallel to
each other in a multiple engine configuration,
a sync. check needs to be performed. This due
to the fact that the outgoing power cables
could be twisted compared to the other
connected engines or utility.
Step 1: Verify rotation sequence of generator
and busbar field on PO page.
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Synchronization test
Step 2: Adjust the number of sync. pulses to
go into hand off load to 100 (proc.var page 2).
This will option will require 100 sync pulses
before the engine goes in off load mode. All
that time, the synchronizer is enabled and one
can test the synchronizing performance.
Step 3: Put engine operation mode in Hand
Off Load and start the engine.
Step 4: Place a meter or light bulb across L1
phase of PO and monitor the voltage and LED
blinking on the TEC. Voltage should drop and
at almost lowest point the LED should blink
(see picture D).
Step 5: Repeat this for at least 2 phases!
Step 6: Change number of sync pulses back
to 1 if finished and stop the engine.
Terberg Control Systems
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Multiple Engine Setup
Summary of setting up the system for multiple engines:
Connection of the CAN 3 cables between the engines.
The termination of CAN on the first and last engine.
Address settings of all connected engines.
Software setup on number of engines on same busbar connected.
Grounding of C32 to same ground point/level.
Selecting mode of operation (Island/Parallel).
Load demand setting in Hand on Load (Parallel operation).
Start/Stop engines on same busbar setup.
Droop settings with CAN 3 sharing or ISOCHRONIOUS with HW load
share lines
Terberg Control Systems
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. 3 Volts DC when running FULL load.
Woodward
specification
on
loadshare
lines
is
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Multiple Engine Setup
The CAN
connection
between the
engines is a 4
core wire and
contains a pair for
the CAN 3
network and a
pair for the
hardware
loadshare lines.
A non Terberg control panel with Woodward compatible loadshare lines can
be connected to terminal X71 5,6 and 7.
Terberg Control Systems
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Load swing in Island
When running in multiple engine configuration and in Island, it might happen that the
load is swinging between the running engines. To eliminate this behavior, one needs to
find out who is instable and possible adjust PID controls.
If the swing is fast, it might be instability on one of the engines. To check, put the
speed control in manual position and look if the load swing stops. Watch closely what is
happening while this engine is not adjusting on load changes! If none of the engines
are responding, one need to stop an engine to see the results.
If the swing gets stable when an engine is set in manual speed mode, one needs to
check which PID control is causing instability. This could be the frequency if the bus
frequency is changing much or it is the load control.
Check bus frequency when engine is in auto again and monitor also the frequency PID
control if the PID switches on the BAND 1 or 2 regularly. If so, decrease the kI and
monitor.
If the frequency is stable than continue with the load control. Decrease the kI and
monitor again.
Note: Remember that the ‘INITIALIZE’ button has to be pressed when kP,kI,kD or time
base are adjusted!
Good practice: Dead band on frequency control is a must. It will however introduce an
offset on frequency, depending on the amount of dead band.
Terberg Control Systems
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.  Air circuit breaker operation slow – Breaker does not close when close command .is given. .Check close and open circuits.
.
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inverse
.  Engine shows wait for start, but does not start when command is given – check the
.
. on the ‘Normal Stop Button’
.
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.
.
output
scaling / PID controls.
.  Load swing during multiple engine configuration and island operation – check analogue
.
.
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.
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.
.

Alarm
‘wrong
busbar
number
filled
in’
–
Check
on
engine
1
the
amount
of
engines
filled
in
at
project
settings.
.
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.
of operation
(island / parallel).
.  Load sharing in imbalance – check the rated power on individual engines, check mode
.
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.
.
controls.
.  With CAN 3 load sharing, engine is very instable – check DROOP settings, check PID
.
.
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.
.
.  Running on load, engine load drops without warning – Check de-rating on exhaust
. temperature.
.
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.
.
check
.  Temperature reading is wrong – check sensor selection analogue input, check wiring,
.
. sensor.
.
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.
.

In
island
and
auto
mode,
engine
does
not
start
–
check
start/stop
configuration
on
busbar
.
.
. setup, check always run.. .
.
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.
.
.
.
.  Only power led on TEC is burning, nothing happens – check download dipswitch, .should be
. off.
.
.
.
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.
.
If wrong
setup, charger might damage.
.  Battery charger failed – check line voltage selector switch compared to supply voltage.
.
.
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.
.
be all
.  Engine voltage control doesn’t work- check in CDVR the AVR input selection – should
.
. ‘switch’.
.
.
.
.
.
.
ET to have
PWM first and CAN for second
.  Engine has reverse kW after closure to bus – check speed control in off-load, check
.
.
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.
.
.
.
.
input
choice
selected
in
EMCP
3.
.
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.
.
.  Engine displays ‘wait for start’ but doesn’t start – check input ‘normal stop button’,
. should. be inversed.
.
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.
.
as well in ECM, remove one.
.  When in droop mode, the speed drops to much at load change – check if droop is. in software
.
.
.
.
.
.
.
check manual speed enable.
.  Running in island, an engine is always on constant load – check setting ‘always run
. in parallel’,
.
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– set alarm
600 to D-fault iso A-fault.
.  When an PO trip happened, engine stops directly but I want to have it in cool down
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
A
PO
alarm
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active,
how
to
reset
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Via
button
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‘active
alarms’
page
or
3
seconds
on
reset
alarms
button.
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Fault finding
Terberg Control Systems
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.........................................................................................................................................
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Levels of Terberg CS
The software levels for the system are:
No password required (default).
Does not exist.
99454
Site operator.
80354
Site manager.
32694
Maintenance / Service engineer.
Does not exist.
Does not exist.
60744
Cat Dealer Authorized Engineer.
14438
Terberg System Engineer.
IMPORTANT : Do NOT give the customer higher than level 3.
Tips and Tricks on IPC/Laptop: Enter the first 4 digits in correct
sequence and type after that any number in different sequence
and end with the correct last digit!
9945782308928749234 will be level ?
Terberg Control Systems
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Contact
Visitors:
Lagedijk noord 3
3401 VA IJsselstein
The Netherlands
Postal address: P.O. Box 243
3401 AE IJsselstein
The Netherlands
Telephone:
+31(0)30 68 69 111
Fax:
+31(0)30 68 70 517
Email:
Info@Terberg-Control-Systems.nl
WWW:
WWW.Terberg-Control-Systems.nl
Service:
Service@Terberg-Control-Systems.nl
+31 (0) 30 68 69 115
Sales:
Sales@Terberg-Control-Systems.nl
Engineering:
Hardware@Terberg-Control-Systems.nl
Software@Terberg-Control-Systems.nl
Terberg Control Systems