8808 Series Genset Control Panel Manual

8808 Series Genset Control Panel Manual

1. Brief description The 8808 system is well designed and has strong power. Besides the basic Gen-set remote function, a good deal of powerful functions are also provided : 32 Gen-sets synchronization parallel connection of Gen-sets and Mainsautomatic realization of the sharing of active power and reactive power load per rata. and Standard computer communication interface. Via PC or common telephone net remote dialing connection, we can supervise the multiple Gen-sets synchronizing system. y Generator control and protect function 1. Manual and auto control of single Gen-set and output air switch; 2. Wide LCD screen display: Engine parameters: oil pressurewater temperaturebattery voltagerun hours; Generator parameters: phase voltage wire voltage frequency power factor active power reactive powerdegree; Synchronizing parameters: parallel connected Mains bus voltageMains bus voltage alternator voltagefrequencypotential difference. 3. Protect stop : Low oil pressure High temperatureOver speedOver frequencyLose of speed signal Start failOver currentHigh/Low voltageBack powerDifferential protection; 4. Failure warning: Charge failHigh temperatureLow oil pressureLow battery voltageSensor failure. 5. HISTORY record (like the black box). 6. Authorization control of Parameter settings 7. Convenient function extend y Synchronization control 1. Automatic synchronization, automatic realization of the sharing of active power and reactive power load pro rata, automatic connection and disconnection fluctuation. 2. Realization of load diversion without power cut. 3. The setting of LoadResStrt ensures stable power supplying when load fluctuates. 4. Start priority can be programmed. 5. Via CAN industrial controller high speed BUS the Gen-sets communication can be realized. 6. With input/output programming interface. 7. Single manual Gen-set can be easily extend to Multiple
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of

Gen-sets

according

to

loads

8808 Series Genset Control Panel Manual

Gen-set supervising and synchronizing system. 8. Synchronizing units can be enlarged to 32 Gen-sets yRemote control function 1. Standard RS232 communication interface; 2. With one communication interface, Multiple Gen-sets can be supervised. 3. Provide open communication protocol. 4. Provide superior control computer software free of charge. 5. On the interface of the supervising software, we can yComposing of the system Gen-sets for synchronization must be equipped with an electro-velometer and a automatic voltage adjustor (AVR), each synchronized Gen-set is a unit, when the load is enlarged, we can add synchronizing unit as required. Every unit includes: 1) 8808 high voltage control panel The 8808 panel adopts advanced Main controller, provides basic functions such as Gen-sets control and protectionautomatic synchronizationsharing of active power and reactive power loadcommunication etc. 2) Automatic breaker The synchronizing Gen-sets must be equipped with a auto-high voltage-breaker, and its rated current depends on Gen-sets output current, all the Gen-sets output wires are connected to a common BUS and consist a synchronizing system. 3) Conflux high voltage output tank Conflux high voltage output tank can control the synchronized Gen-sets output conflux and brakes ON/OFF state. 4) Automatic source diversion tankATS (equipment selectable) ATS can realize automatic diversion between Mains and Gen-set. observe all the Gen-sets operate status and control Gen-sets runningload and enact the Gen-sets settings.

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8808 Series Genset Control Panel Manual

2. Means of operation yOperation interface Pushbuttons 2.1 2.2 2.3 2.4 2.5 MODE MODE Horn reset Fault reset Cyclic forward selection the Gen-set operation mode Deactivates the HORN Acknowledges faults and alarms (OFF MAN AUT) Cyclic forward selection the Gen-set operation mode (AUT MAN OFF)

Start In MAN mode these buttons are disabled. the Gen-set getting right, the start motor will be out of use. If the first start fails, after a enacted time, it will try to start again automatically .If it fails for the third time, a fail signal will be sent out, and the fuel valve will close.

1) When Gen-set is static, press MAN to open the fuel valve and start the start-motor to crank, after

2) When Gen-set is in cooling state, press MAN, the cooling time will be canceled, then the Gen-set can supply power (with load ). 2.6 Unload/Stop In MAN mode these buttons are disabled. 1) When the Gen-set runs with load, press MAN, and the Gen-set switch will open, the Gen-set will begin cooling delay, after the cooling time, Gen-set will stop automatically. 2) When Gen-set is in cooling state, press MAN, the cooling delay will be canceled, and the Gen-set will stop immediately, Hint: When Gen-set is in normal operation, if emergency cases occur, press MAN twice, this motion equals to the emergency stop; in normal case, the MAN bottom should be pressed only once, so that the Gen-set be shutdown after the cooling delay. 2.7 MCB ON/OFF 2.8 GCB ON/OFF During Multiple operation (MINT), MAN bottom have no affect. Manual Open/Close the brake (if Mains have power, press MAN and the controller will combine and synchronize multiple Gen-sets). 2.9 PAGE Cyclic selection of the display mode (MEASUREMENTADJUSTMENTHISTORY--ALARMS) 2.10 Select the setpoint, select the screen or increase setpoint value 2.11 Select the setpoint, select the screen or decrease setpoint value 2.12 LEDs 2.13. MAINS PRESENT If the Mains voltage is present and within limits, the green lights. 2.14. MAINS FAILURE Has no affect in this application. 2.15. GEN VOLTAGE PRESENT LED is on, if gen. voltage is present and within limits 2.16. GEN-SET FAILURE LED starts flashing when gen-set failure occurs. After FAULT RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active)
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ENTER

Confirm setpoint value

8808 Series Genset Control Panel Manual

2.17. GCB ON LED is on, if GCB is closed. Flashes when GCB FEEDBACK does not correspond to GCB CLOSE/OPEN. 2.18. MCB ON not active Use MODEor MODE to select requested gen-set operation mode When to use buttons GCB ON/OFF and MCB ON/OFF? In AUT mode these buttons are disabled. In MAN mode are enabled, but before closing of any circuit beaker, voltage must be within limits. Closing to dead bus When no voltage is detected on the bus, the GCB is immediately closed. Sychronizing Under AUT mode. When voltage is detected on the bus ( within Voltage window) InteliGen starts synchronizing and waits for closing of GCB. Display menus There are 3 display menus available: MEASUREMENT, ADJUSTMENT and HISTORY Each menu consists of several screens. Press repeatedly PAGE button to select requested menu. How to view measured data? 1. Use repeatedly PAGE button to select the MEASUREMENT menu. 2. Use and to select the screen with requested data. How to view and edit set points? 1. Use repeatedly PAGE button to select the ADJUSTMENT menu. 2. Use or to select requested set points group. 3. Press ENTER to confirm. 4. Use or to select requested set point. 5. Set points marked * are password protected. 6. Press ENTER to edit. 7. Use or to modify the set point. When or is pressed for 2 sec, auto repeat function is activated 8. Press ENTER to confirm or PAGE to leave without change. 9. Press PAGE to leave selected set points group. Statistic Kilowatthours kWh Run hours Number of starts How to handle the HISTORY menu? 1. Use repeatedly PAGE to select the HISTORY menu.
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How to select the Gen-set mode ? (OFF MAN AUT)

(total and per phases)

Apparent power hours kVAh (total only)

8808 Series Genset Control Panel Manual

2. Use or to select a requested record. 3. Use ENTER to select requested screen (record items) within displayed records How to change the display contrast ? Press ENTER and or at the same time to adjust the best display contrast How to check the serial number and software revision? Press ENTER and then PAGE. On the display you can see InteliGen INFO screen for 10 seconds. InteliGen INFO screen contains : 1) Controller name (see Basic setting group) 2) InteliMains serial number (8 character number) 3) SW version: the first is the firmware version number, the second is configuration table number. 4) Application: IM 5) Branch: InteliMains How to find active alarms? Active alarm list is the last screen in the MEASUREMENT menu. Select MEASUREMENT menu. Press You will see the list of all active alarms with the number of alarms at the top-right corner. Inverted alarms are still active. Non-inverted alarms are not active, but not yet confirmed. Press FAULT RESET accepts all alarms. Non-active alarms immediately disappear from the list. Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is active. Main measure screen InteliGen Mode Gen-set power - meter Gen-set states Power Factor, load character Generator screen Gen-set states Engine Speed (single bargarph) Gen freq Gen V1, V2, V3 (tripple bargraph) Gen I1, I2, I3 ( tripple bargraph) Bus screen Neutral current Bus frequency Gen V1, V2, V3 (tripple bargraph)
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8808 Series Genset Control Panel Manual

Analog sensors screen Oil pressure (AI1) (single bargarph) Water temperature (AI2) (single bargarph) Fuel level (AI3) (single bargarph) Gen-set power screen Active power (total and per phase) Power factor (total and per phase) Reactive power (total and per phase) Power factor (total and per phase) Statistic Kilowatthours kWh (total and per phases) Apparent power hours kVAh (total only) Run hours Number of starts Sychroscope Angle (between U1 and U1m) Slip (between U1g and U1m) U1g [V] U1m[V] Sequencing Engine priority Total available power ( sum of Nominal power ) Total run power ( sum of Nominal power-running) Active reserve Alarm list Gen-set operation state prompting messages:
English Not ready Init Ready Prestart Cranking Meaning Gen-set do not get ready Controller initializing Gen-set get ready Valid prestart output Valid start motor output,cranking English Loaded Stop Shut down Cooling Idle Meaning Gen-set is loaded Gen-sets stopped Shut down failure Gen-sets getting cold Gen-sets getting heat

(single bar graph )

CAN bus status (binary)

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8808 Series Genset Control Panel Manual

Pause Starting Unl alarm

Cranking pause Start motor exited ,Gen-set speedup Unload failure

RPM fail AVR fail Unloading

Over/low speed shut down Over/low loading voltage during

Gen-sets unloading

y HISTORY When operations are done to install/upgrade software start/stop the engine open/close the brake or warning and failure shutdown arise, the controller will automatically record all the running parameters of the time, and this will benefit the checking and solving of failures In start course, the controller will timely (adjustable) record Gen-sets parameters. 100 pieces of records can be deposited in the HISTORY bar. When there are more records, the oldest one will be covered.
English Meaning for short No Records serial number for short Vb1 Voltage of the mains first phase when event occurs Voltage of the mains second phase when event Vb2 occurs Voltage of the mains third phase when event Vb3 occurs Current of the mains first phase when event occurs Current of the mains second phase when event Ig2 occurs Current of the mains third Ig3 occurs Neutral current when event occurs phase when event English Meaning

Reason

Event description

Time

Time

Date

Date Gen-sets output power when

Ig1

Pwr

event occurs Gen-sets power factor when

Cos

event occurs Gen-sets load property when

Lchar

event occurs Gen-sets rotation speed when

In

Spd

event occurs Gen-sets frequency when

Batt

Battery voltage when event occurs

Gfreq

event occurs Voltage of the alternators first

Oil

Oil pressure when event occurs

Vg1

phase when event occurs Voltage of the alternators

Temp

Water temperature when event occurs

Vg2

second phase when event occurs

Fuel

Fuel level when event occurs

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8808 Series Genset Control Panel Manual

Voltage of the alternators third Vg3 phase when event occurs Mains frequency when event Bfreq occurs BinOut BinInp

Binary input state

when event occurs

Binary output state when event occurs

y Warning message
English for short Wrn Oil Press Sd Oil Press Fls Oil Press Wrn water Temp Sd Water Temp Fls Water Temp Wrn Fuel Level Sd Fuel Level Fls Fuel Level Wrn Batt Volt Emerg Stop Wrn Charg Fail Meaning Low oil pressure warning Low oil pressure shutdown Oil pressure sensor failure High temperature warning High water temperature shutdown Water temperature sensor failure Low fuel level warning Low fuel level shutdown Fuel level sensor failure Low battery voltage warning Emergency stop Charger fail warning English for short Unl Gen Overload Unl Ineutral Sd AVR Fail Sd Overspeed Sd Underspeed Sd Start Fail GCB Fail MCB Fail Gen set start Gen set stop Unl Back power GEN L1 neg Meaning Alternaters overloaded Neutral overcurrent AVR failure Over speed shutdown Low speed shutdown Start fail Alternator GCB failure Mains switch (MCB) failure Gen-set starts Gen-set stop Back power failure Sequence fault of the

alternators first phase Sequence fault of the

Gen Undervolt

Gen-set low voltage Over voltage of the alternators

GEN L2 neg

alternators second phase Sequence fault of the

Unl Vg1 Over

first phase Low voltage of the alternators

GEN L3 neg

alternators third phase Sequence fault phases of the

Unl Vg1 Under

first phase Over voltage of the alternators

G ph opposed

alternators

Unl Vg2 Over

second phase Low voltage of the alternators

G ph+L1 neg

Unl Vg2 Under

second phase Over voltage of the alternators

G ph+L2 neg

Unl Vg3 Over

third phase Low voltage of the alternators

G ph+L3 neg

Unl Vg3 Under Unl Fgen Over Unl Fgen Under Unl Igen Unbal

second phase over frequency of Alternator Low frequency of Alternator Unbalance voltage of alternators phases

G phase Ang Active Call Bad Active Call SyncTimeout Synchronizing timeout
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Failure call

8808 Series Genset Control Panel Manual

Unbalance voltage of alternators Unl Vgen Unbal phases Over current of the alternators Unl Ig1 Over first phase Over current of the alternators Unl Ig2 Over second phase Over current of the alternators Unl Ig3 Over third phase Firmw loaded Appl loaded R SyncTimeout

Synchronizing timeout

Controllers initialized

yHow to set the parameters of Sequencing page The SEQUENCINGs settings mainly controls the Gen-sets operation state according to the change of load. In one parallel system, all the Sequencings parameters must be the same, except Priority, Controller adr, GCB open level, GCB open del. The controller can copy the Sequencings parameters automatically. Hint: If Gen-sets are not combined with CAN bus, then each Gen-set work individually and the auto-copy function has no affect, the manual operation is necessary. y Function description There are three modes of the gen-set: OFF - MAN - AUT. To select the mode press MODEand MODE OFF Mode No start of the gen/set is possible. Outputs STARTER, GCB CLOSE/OPEN and FUEL SOLENOID are not energized. No reaction if buttons START, STOP, GCB ON/OFF are pressed. 1. Start 1) To start the gen-set: press START. 2) When the generator voltage is within limits, the corresponding light flashes. 3) press GCB ON/OFF to close the GCB. If the generator voltage is out of the limits, InteliGen does not respond to the GCB ON/OFF. 4) If the Buss voltage can not detected by controller , GCB ON/OFF will close. If the generator voltage is in the limits, then the Gen-sets will began to synchronize. 2. Stop 1) Press STOP 2) If Gen-sets are still supplying power, unload is the first step. When the supplying level reaches GCB open level, GCB will open automatically; IF no parallel Gen-sets ,GCB off immediately. 3) Engine will stop after the cooling delay. Hints: Only with load delivery wires active power can be delivered, only when combining to CAN bus, reactive power can be delivered.
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8808 Series Genset Control Panel Manual

AUT Mode
1. Set a 3-phases Mains inductor to both of the two Mains circuits, when failure arises to one route

of Mains, such as power cut or lack of phase or grounding or other unusual cases, the inductor will send a signal to the Gen-set stand-by system.
2. When both of the two Mains work right, Gen-set will stand by. 3. When failure arises to one route of Mains, such as power cut or lack of phase or grounding or

other unusual cases, a preferential Gen-set which can supply enough reserve power will start after a delay.
4. A first get stabled Gen-set will be put into use, and the others will combine to the bus one by

one according the sequence of stable time.

5. But the Stand-by system will not control ATS to switch to the Gen-set side or close the brake,

the Gen-set keeps in heat stand-by state.

6. When the Gen-set keeps in heat stand-by state, If the another Main also gets abnormal, the

stand-by system will control ATS to switch to Gen-set side or close the brake, stand-by Gen-set will supplying power immediately.
7. When both of

the Mains fail, the stand-by Gen-set will start without delay immediately. to switch to Gen-set side or close the output brake, that is, pro rata.

Stand-by system control ATS

Gen-set will supplying power to load.

8. Based on the Gen-sets rated power, active and reactive power will be delivered 9. When the load increases to such a degree that the required power is greater

than the total

power of the parallel connected Gen-sets. After a delay (Next start del), a Gen-set with priority 1 will start and synchronize after a cooling delay.
10. When one of the Mains gets right, the Gen-set will run with load for 2 minutes ( adjustable 1 to

automatically; If the load decreases to such a degree that the

supplied power is greater than the required, the Gen-set with priority 1 will unload and stop

20 minutes), and then the system control ATS to switch to the Mains side or open the output brake, and keeps running for stand-by.
11. When both of the two Mains get right, if Gen-sets are in heat stand-by state, they will stop after

10 minutes cooling delay (adjustable 1 to 10 minutes); if the Gen-sets are supplying power, they will run with load for 2 minutes (adjustable 1 to 20 minutes) and then control ATS to switch to Mains side or open the brake and stop the engine after 10 minutes cooling delay (adjustable 1 to 10 minutes). yCommunication module Direct connection to PC Use the standard cable RS232 cable to connect PC with 8808 high voltage control panel Remote dialing connection with MODEM Use MODEM to connect PC with 8808 high voltage control panel yPC software
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8808 Series Genset Control Panel Manual

On the PC (for direct or modem connection) has to be installed the Comaps software package (Based on Windows 95 or newer platform) The software enables: 1) Read the quantities, 2) Adjust all set points, 3) Read the history 4) Control the engine 5) Configure the controller 6) Select software configuration 7) Modify alarm inputs and outputs 8) Direct or modem communication 9) Receive active calls yDescription of the warning page The 8808 control panel provides warning messages as follows: Warning Unload shutdown with cooling delay or shutdown. Hints: Every binary input interface can be enacted as a warning message by superior control unit. and every warning message will display on the warning page, and write in the HISTORY record. Warnings As a warning failure happens, controller will only send a signal to the warning binary output without any other motion. Warning failures: 1) Warning binary input 2) Warning analog input 3) Sensor failure 4) Over battery voltage 5) Order of phases fault (Gen-set) 6) Order of phases fault (Mains) 7) Brake failure Unload failures: When this kind of failure arises, controller will open the brake automatically with a cooling delay). Listed as follows: 1) Overload 2) Over current (3 phases to be checked) 3) Current unbalance (3 phases to be checked) 4) Voltage unbalance (3 phases ) 5) Alternator over/low voltage (3 phases to be checked ) 6) Alternator over/low frequency ( 3 phases to be checked ) 7) Back power 8) Protect motion
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8808 Series Genset Control Panel Manual

9) Unload failure warning input interface. Slow stop failure ( with cooling delay) When slow stop failure occurs, unload firstly and then open the brake, and stop after a cooling delay; If there are still other Gen-sets in the system, they will start and synchronize and load automatically. The failed Gen-set will stop after cooling delay (If after Slow stop delay the load still not diverted, the controller will control to open the brake and stop). Sloe stop failures: 1) Slow stop failure binary input 2) Slow stop failure analog input Emergency stop When a emergency stop has been done, the controller will cut off fuel and the start motor and the preheat and the output brake. Cases of emergency stop listed as follows: 1) Neutral over current 2) Over speed 3) Low speed 4) Protect motion 5) Emergency stop binary input 6) Emergency stop analog input ySynchronizing 1. Manual synchronizing 1) Start Gen-set #1 2) Close the electro-air switch 1BK by hand, and the indicator lights. 3) Start Gen-set #2 4) Press the ON bottom on 2# Gen-sets main control panel, and the related indicator will began to flash, showing that Gen-sets are synchronizing. When all is right, the 2BK indicator flashes. 5) Load the Gen-set 6) Cut off 1BK and 2BK by hand. 7) Stop Gen-set by hand. 2. Auto synchronizing A. Single Gen-set start module without Mains power: 1) Analogize Mains power cut 2) Reserve start (Load ResStrt 1) activated. When the reserve start power value equals to the Gen-sets capacity, according to the PRIs sequence, 1# Gen-set will start, after a delay,1BK will close automatically and the related indicator flashes (If 1# Gen-set fails to start for 3 times, 2# Gen-set will start instead). 3) Gen-set output switch (in the low voltage control panel) close, and Gen-set began to supply power to load. The signal will be feedback to 8808 panel, and then the Load ResStrt 2 will be activated.
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8808 Series Genset Control Panel Manual

4) Add total load step by step up to 696KW (75% single Gen-set rated power), 696KW (load) + 186KW (Load ResStrt )=882KW< 928KW (1# capacity), 2# Gen-set will not start. 5) Add total load step by step to more than 789KW (85% rated power ), 789KW (load) + 186KW (Load ResStrt )=975KW> 928KW (1# capacity), after a delay 2# Gen-set will start and synchronize automatically ,50% of 1# Gen-sets load will be steadily passed to 2# Gen-set. 6) Reduce the total load step by step to less than 696KW (75% rated power ) 696KW (load) + 278KW (Load ResStp )=974KW>928KW (1# capacity), 2# Gen-set will not draw out. 7) Reduce the total load step by step to less than 464KW (50% rated power ) 464KW (load) + 278KW (Load ResStp )=742KW<928KW (1# capacity), 2# Gen-sets load will be steadily passed to 2# Gen-set, 2# Gen-set exit from the parallel connection and stop after cooling delay. 8) Analog ize 1# Gen-sets failure, and 2#Gen-set will start and load automatically, they act as double stand-by system. 9) When Mains get right, after the Mains return delay 1# Gen-set will draw out and stop after cooling delay. B. When the mains power cut, the two Gen-sets will start the synchronizing pattern

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