PGC 4000v2 POWER

GENERATION CONTROLLER

THOMSON POWER SYSTEM PGC 4000v2 OFFERS THE FOLLOWING:

Superior control & monitoring system for Thomson Power

Systems advanced Series 2400 Switchgear (refer to separate literature)

High Speed/Noise Immune Ethernet-based

Communications provides the most reliable real-time system data transfer available

Flexible Design allows use in Distributed Generation,

Automatic Standby or Prime Power Applications

Integrated design for complete system control and monitoring

Fully Integrated Web/Internet-based Remote Monitoring

and Controls provide on-line service support and system
upgrades

Compliant with IEEE 1547 Distributed Generation

Interconnect Standard

Provides controls for Single or Multiple Generator &

Utility Feeder applications

Certified to UL 508 & CSA 22.2 #14 Industrial Control

Equipment Standards

Integrated Revenue Grade Utility and Generator

Metering with Power Quality Measurement (exceeds
ANSI C12.20 Revenue Class 0.5 accuracy)

Integral Digital Engine-Generator controls with Automatic

Synchronizing & kW/kVAR Load Sharing

User Friendly 17 Color Touch Screen Operator Interface

with run-time configurable Graphics

High Accuracy Digital Protective Relaying for Generator

& Utility Supply per IEEE & ANSI standards

STANDARD FEATURES
The PGC 4000v2 is an intelligent, integrated full feature Power Generation Controller. The PGC 4000 controller is the power
behind the Thomson Power Systems Series 2400 Paralleling Switchgear System which provides flexible standard designs that
allow automatic paralleling of single or multiple generators for applications including Distributed Generation, Automatic Standby and Prime Power. The new PGC 4000v2 provides industry leading processing power with dual 1 Gbps Ethernet Network
Communication ports for superior communication reliability and speed.
The PGC 4000v2 can be configured to operate on low or medium voltage systems and can be applied with a variety of generator set manufacturers and prime movers including diesel or gas reciprocating engines and gas or steam driven turbines. The
PGC 4000v2 integrates a vast array of advanced control and monitoring features with Thomson Power Systems unique run-time
configurability feature. Some of the advanced integrated features include utility/generator revenue grade power metering,
protective relaying, engine control, automatic synchronizing and automatic kW/kVAR load sharing.
The PGC 4000v2s full color, touch screen, graphical operator interface display combined with Thomsons Internet/web ready
Ethernet communications to make it the most user friendly, integrated power generation system controller on the market. By
incorporating advanced communication interfaces, the PGC 4000v2 can operate in harmony with any PLC or building management
system, providing maximum equipment utilization and total energy management.
The PGC 4000v2 is comprised of a door mounted operator interface display and the PGC 4000v2 controller, which is mounted in the switchgear control compartment. The operator interface display and control module are interconnected with a high
speed Ethernet communication cable. One controller module is required for each generator set. One operator interface display is
provided for the complete system. Additional operator interface screens can be supplied as required.

APPLICATIONS
The PGC 4000v2 can be applied to numerous types of power generation systems. Its flexible configuration allows application in
new installations as well as existing systems when generators require upgrading for parallel or peaking operation with the utility
supply. Typical system applications include the following:

Distributed Generation (DG): Distributed Generation systems provide the capability of synchronizing single or multiple
generators to the utility grid to allow soft-load transfer, parallel generation, peak shaving, or Cogeneration operation.

Auto Standby (AS): Automatic Standby systems control single or multiple generator sets to provide automatic standby
power during a utility power failure. Auto standby systems can be designed with an integral transfer system between the utility
supply and emergency bus. Auto standby systems can also work with external distributed transfer schemes. With the use of
the PGC 4000, load demand starting is incorporated to maintain optimal efficiency and reliability of your gen-sets during a
power failure. Load management schemes can be provided to prevent your system from being overloaded, resulting in costly
and dangerous downtime.

Prime Power (PP): Prime Power systems provide power and control for applications where local utility supply is unreliable,
unavailable, or uneconomical to install. With the PGC 4000v2, these systems can incorporate automatic synchronizing,
soft-load transfer, fuel economizing, or run-time hour balancing.

PGC 4000v2 STANDARD MONITORING AND CONTROL FEATURES

Operator Interface: The PGC 4000v2 color, touch screen, operator interface can display all information related to single or multiple
unit applications. Information is displayed using multiple analog and digital methods. The display can be configured for user specified screen layouts utilizing the PGCs run-time programming capability. Access to all screens is provided via multi-level user access
security system. The display(s) are factory programmed to provide the following system information:

Generator Power Metering: Digital and Analog 3 phase

RMS power metering (Voltage, Current, Frequency, kW,
kVA, KVAR, Power Factor)

Generator Power Quality: Phase Harmonics, Phasor Diagrams (Voltage & Current) Total harmonic distortion (Voltage & Current), Waveform capture

Generator Protective Relaying: IEEE protective functions

25, 32, 27, 40, 51, 59, 81o/u

Engine Control: Alarm/shutdown annunciation, engine

gauge data (speed, oil pressure, temperature, fuel level
etc.), start/stop control, and operating mode of the engine

Engine/Generator Shutdown & Alarm Annunciation:

Screens showing active alarms and shutdowns

Engine/Generator Event Logging: A historical list of system

alarms or shutdowns with time, date and event listing

Utility Power Metering: Digital and Analog 3 phase RMS

utility power metering (Voltage, Current, Frequency, kW,
kVA, KVAR, Power Factor)
Utility Power Quality: Phase Harmonics, Phasor Diagrams

(Voltage & Current) Total harmonic distortion (Voltage &

Current), Waveform capture

Utility Protective Relaying: IEEE protective functions 25, 32,

27, 59, 81o/u

Single Line Diagram: Graphical display of the generator

electrical system showing breaker position, bus status, operating generator modes and summary alarm screen

Configuration Settings: Password protected access to set

time delays, load set-points, programmable logic

PGC 4000v2 STANDARD MONITORING AND CONTROL FEATURES

Power Metering/Power Quality: The PGC 4000v2 provides digital and analog display of power metering and power quality data
for both the generator and utility sources via the operator interface display. In addition, load voltage and frequency metering data
are monitored and displayed which is utilized for synchronizing and dead bus closing logic. The Power Metering data complies
with revenue accuracy standards as per ANSI C12.20 Class 0.5 accuracy. The following power metering and power quality data is
provided:

Generator Supply: 3 phase voltage, current, frequency, kilowatts, kilovars, kVA, power factor, kW hours, kVAR hours, Phase
Harmonics, Phasor Diagrams (Voltage & Current), Total harmonic distortion (Voltage & Current), Waveform capture

Utility Supply: 3 phase voltage, current, frequency, kilowatts,

kilovars, kVA, power factor, kW hours, kVAR hours, Phase

Harmonics, Phasor Diagrams (Voltage & Current), Total harmonic distortion (Voltage & Current), Waveform capture.

Load Bus: 3 phase voltage and frequency, Phase Harmonics

and Phasor Diagrams (Voltage), Waveform capture

Protective Relaying: The PGC 4000v2 provides configurable protective relaying functions for both Generator and Utility supplies via the operator interface graphical screen. Single cycle calculations are used to drive output relays allowing fast protection
operation when required. The following protective functions are provided as standard per PGC 4000v2 controller utilized:

Generator
25 - Sync-Check
32R - Reverse Power
27 - Undervoltage
40 - Reverse VARs
51 - Time Overcurrent
59 - Overvoltage
81o/u - Under/Over Frequency (2 stage)

Utility
25 - Sync-Check
32R - Reverse Power
27 - Undervoltage
51 - Time Overcurrent
59 - Overvoltage
81o/u - Under/Over Frequency (2 stage)

Automatic Load Sharing: The PGC 4000v2 provides Automatic kW & kVAR load sharing control when generators are paralleled
to each other or a utility supply. Automatic load sharing utilizes the PGCs high precision digital power data which is shared over
Ethernet communication links to ensure fast and reliable operation. The PGC 4000 is able to interface with engine electronic governors and alternator excitation systems for paralleling power control. The following kilowatt and Kilovar control functionality are
provided as standard:

Gen to Gen isochronous load sharing: percentage based,

constant voltage and speed kW and kVAR load sharing.
kW Load ramping: Adjustable ramp rates for loading and
unloading of the generator and utility supplies
kW Base Loading: Adjustable generator and utility base
loading setpoints for parallel operation of the generator
system with the utility grid

kVAR (Power Factor) Control: Adjustable setpoints for

constant generator levels or utility levels
Min/Max Load limits: Programmable setpoints to provide
desired min/max levels of equipment operation
Import kW Control: Programmable to allow import power
operation when paralleling with the utility supply

Automatic Synchronizing: The PGC 4000v2 provides fully automatic or manual synchronization control. Automatic synchronization utilizes the PGCs high precision digital frequency, voltage and phase angle data to ensure fast and reliable operation. Manual
synchronization allows user adjustable voltage and frequency via the PGC 4000v2 controller and user initiated breaker closure with
integral out-of-phase sync check protection. Synchronization is possible between any 3 voltage measurement sources. Synchronizing controls are designed to interface with most common engine electronic governors and alternator excitation systems. The
following synchronizing functionality is provided as standard:

Speed Matching: Adjustable gain & stability setpoints

to allow fast and accurate speed/frequency control for
automatic synchronizing
Synchroscope: Graphical waveform display between
generator and utility supply
Voltage Matching: Adjustable gain & stability setpoints
to allow fast and accurate voltage control for automatic
synchronizing
Auto/Test/Manual Sync Modes: Programmable to operation mode desired

Fail to Sync Alarming: Automatic logic continually monitors

the automatic synchronizing process and activates alarms
should abnormal conditions occur
Voltage Monitoring: 3 phase voltage is monitored prior
to synchronization to ensure correct phase rotation and
correct voltage levels
Dual Dynamic Synchronizers: Two independent set of
synchronizing algorithms have been developed to enable
optimum system tuning to deliver highly reliable automatic
synchronizing for changing generator load conditions.

PGC 4000 STANDARD MONITORING AND CONTROL FEATURES

Engine Control: The PGC 4000V2 is configured with integral engine controls. The PGC 4000 may also be configured to operate
with external unit mounted engine/generator controls. The following engine/generator controller features are provided as standard:

Auto Start Control: Cycle cranking with integral speed sensor for crank disconnect and overspeed
31 Digital/Analog Fault Alarms/Shutdown Inputs: Alarms/
shutdowns to meet/exceed requirements of NFPA 99, 110
& CSA 282
Engine Parameter Display: Digital and analog display of oil
pressure, oil temperature, coolant temp, battery voltage,
RPM, and fuel level

22 Output Contacts: Alarm and shutdown contacts for

remote indication
Configurable Set Points/Time Delays: Password protected access to set time delays (engine start, crank, rest,
cooldown, oil bypass etc.)

Remote Communication: The PGC 4000v2 has high speed communication ports allowing flexible integration to many types of
local and remote monitoring systems. The PGC 4000v2 display provides an isolated outside world Ethernet port for Internet/network access. Standard Internet browser software with WindowsTM 7 Pro is required to remotely monitor the system.
The PGC 4000v2 contains the following communication ports and protocols:

Controller Port - Ethernet /UDP:High-speed communications

to Display(s), and PGC 4000v2 Device Network
Display Port - Ethernet /UDP: High-speed communications
to other Display(s), and PGC 4000v2 Device network.

The PGC 4000 with Series 2400 Paralelling Switchgear can be

provided with the following communication ports for customer connection with local and remote communication interface
systems:

Display Port - Ethernet: High-speed communications port

for Customer use allowing remote monitoring/control
stations using the Internet or local area network

MODBUSRTU Serial
MODBUS TCP (Ethernet)
Remote Access (Lan/Internet) Web Server
Email/Pager on alarm

Programmable Logic Inputs/Outputs: The PGC 4000v2 has user-friendly programmable logic and also provides sophisticated
control features. Programming is run-time configurable and allows users to tie any setpoint, fault or digital value to any output
relay. Execution time of the programmable logic is less than 2 power cycles activiating outputs in milli-seconds for
critical control operations.
The PGC 4000v2 provides the following functions:

Digital Inputs: Can be programmed to activate internal

logic or alarm functions
Digital Outputs: Outputs can be programmed relay using
graphical Boolean logic (e.g. AND/OR/NAND/NOR gates)
with timers
Analog Signals: Analog signals can be programmed to
alarm at desired levels with time delays as required

GENERAL
Power Supply Input Voltage

18-36Vdc

Temperature Range (Controller)

- 15C to 55C

Environmental Rating (Controller)

NEMA 1

HARDWARE INPUTS
Source 1, 2 Voltage and Current Sensing (Generator & Utility)
8 - PT Voltage Inputs

600V RMS line-to-line (nominal)

8 - CT Inputs

5A Nominal, 10A Over range

Operating System Frequency

50/60Hz

Source 3 Voltage Sensing (Load)

4 - PT Voltage Inputs

600V RMS line-to-line (nominal)

Analog inputs
4 Engine Sender Inputs (Coolant Temp, Oil Temp, Oil Press, Fuel Level)

33 - 240 Ohm/Datcon

External Battery Voltage input

0-40Vdc

8 Analog Inputs

0-20ma, 0-5Vdc

Isolated Digital inputs

Emergency Stop

Normally closed contact sense

31 Digital Inputs

Normally open contact sense

RPM
Magnetic Pickup Sensing

100 - 20,000Hz, 1.0 - 20VAC RMS

HARDWARE OUTPUTS
Output Contacts
Crank - Form A

250VAC 5A, 30Vdc 5A

Run - Form A

250VAC 5A, 30Vdc 5A

22 Digital Outputs - Form A

250VAC 5A, 30Vdc 5A

Analog Outputs
8 Analog Outputs

0-20ma, 0-5Vdc

Voltage Regulator Control Interface #1

+/-9Vdc

Voltage Regulator Control Interface #2

+/-3Vdc

Engine Governor Control Interface #1

+/- 3Vdc

Engine Governor Control Interface #2

0-10Vdc

Engine Governor Control Interface #3

0-500 HZ pulse width modulation

COMMUNICATION
Ethernet ( 2 port)

1 Gbps

PGC 4000v2 FUNCTION BLOCK DIAGRAM (TYPICAL SINGLE GENERATOR/

UTILITY SYSTEM)

12
25
25A
27
32
40
51
59
81U
81O

SAFETY/PERFORMANCE STANDARDS
UL 508, CSA C22.2 #14 Industrial Control Equipment Certification
ANSI C12.20 Class 0.5 Metering Accuracy
NFPA 110-99 Level 1 & 2 National Fire Protection Agency-Emergency & Standby Power Systems
NFPA 99 National Fire Protection Agency-Health Care Facilities
CSA C282 Emergency Electrical Power Supply for Buildings
IEEE C62.41-1999 IEEE Recommended Practice on Surge Voltages in Low-Voltage AC Power Circuits
IEEE C37.90.1-1989, IEEE Standard Surge Withstand Capability (SWC) Tests for Protective Relays and Relay Systems
IEEE C37.90.2, IEEE Trial-Use Standard on Withstand Capability of Relay Systems to Radiated Electromagnetic Interference
from Transceivers
IEEE C37.90-1989, IEEE Standard for Relays and Relay Systems Associated with Electric Power Apparatus
IEEE 1547 Standard for Interconnecting Distributed Resources with Electric Power Systems Compliance
FCC, Radiated and Conducted Emissions (CFR47 Part 15/B)
CISPR 22, CE for conducted and radiated Emissions Class A
CE EN61000-6-3:2001 Emission Requirements (EN55022 Class A, B)
CE EN61000-6-3:2001 Immunity Requirements (EN61000-4-(2-6)
IEC 60255-22 Electrical Disturbance Tests for Measuring Relays and Protection Equipment (IEC 60255-22-(2-6)

9087A - 198th Street

Langley, BC Canada V1M 3B1
PH: 604-888-0110
FAX: 604-888-3381
www.thomsonpscom
2014 Regal-Beloit Corporation

CL059 REV 3 14/05/01