Control System Overview

2015
Agenda
• Single Genset
• EMCP4.1, 4.2, 4.3
• Synchronising
• EMCP4.4
• Solutions Options
• 3rd Party Controllers
• System Integration
• PLC/SCADA control systems
Single Genset
EMCP 4.1 Features
Controls
• Auto/Start/Stop
• Engine cooldown timer
• Emergency stop
• Engine cycle crank

Digital (LCD) Indication

• Generator AC voltage
 3 phase (L-L&L-N)
 ± 2% Accuracy
• RPM & battery voltage
• Gen. AC current (per phase & avg)
• Generator frequency
• Engine oil pressure (psi, kPa or bar)
• Engine oil temperature (°C or °F)
• Engine coolant temperature (°C or °F)
• Multiple language support
• Engine start & crank attempt counter
EMCP 4.1 Features
Engine Protection
• Low oil pressure
• High coolant temp
• Low coolant level
• Fail to start
• Overspeed
Other Features
• Programmable security levels
• Reduced power mode

Generator Protection
• Over/under voltage
• Over/under frequency
• Generator phase sequence
EMCP 4.1 Input/Output
Analog Inputs
• Oil pressure & water temperature
• 1 programmable input (0-5V or resistive)
• Oil temp, fuel level, custom

Digital Inputs
• Emergency stop
• Remote start
• 6 programmable inputs*

Relay Outputs
• 6 programmable relays*
(Form A, 2A @ 30VDC)

* See specific package spec sheet for availability for

customer use
 EMCP 4.1 Communication Diagram
DEALER
SERVICE TOOL
“ET” CDVR

ADEM

CAN1
EMCP 4.1

Local Remote
EMCP 4.2 Features
Controls
• Auto/Start/Stop
• Engine cooldown timer
• Emergency stop
• Engine cycle crank
• Programmable cycle timer

Digital (LCD) Indication

• Generator AC voltage
 3 phase (L-L&L-N)
 ± 1% Accuracy
• RPM & battery voltage
• Gen. AC current (per phase & avg)
• Generator frequency
• Power metering (kW, kVA, kVAr, pf) Communication
• Hour meters (kW-Hour, kVAr-Hour) • Accessory CAN data link
• Engine oil pressure (psi, kPa or bar) • RS-485 annunciator data link
• Engine oil temperature (°C or °F) • RS-485 SCADA (Modbus RTU)
• Engine coolant temperature (°C or °F)
• Multiple language support
• Engine start & crank attempt counter
• Real time clock
EMCP 4.2 Features
Engine Protection
• Low oil pressure
• High coolant temp
• Low coolant level
• Fail to start
• Overspeed

Other Features
• Programmable security levels
• Reduced power mode
• Programmable kW relay
Generator Protection • Tier 4 integration
• Over/under voltage
• Over/under frequency
• Generator phase sequence
• Over current (timed & inverse)
• Reverse power (real & reactive)
EMCP 4.2 Input/Output
Digital Outputs
• 2 programmable outputs*
Analog Inputs
• Oil pressure & water temperature
• 1 programmable input (0-5V or resistive)
• Oil temp, fuel level, custom
Digital Inputs
• Emergency Stop
• Remote Start
• 6 programmable inputs*

Relay Outputs
• 6 programmable relays*
(Form A, 2A @ 30VDC)
• 2 programmable relays*
(Form C, 2A @ 30VDC)

* See specific package spec sheet for availability for

customer use
 EMCP 4.2 Control System
DEALER
Local CAN Remote CAN Remote RS-485
SERVICE TOOL Annunciator Annunciator Annunciator
“ET” CDVR
Generator Expansion
Engine Temps I/O
Temps

CAN2

RS-485 Annunciator Data Link

ADEM
RS-485 SCADA (Modbus RTU)
CAN1
EMCP 4.2 Customer
Monitoring
Local Remote System
EMCP 4.3 Features
Controls
• Auto/Start/Stop
• Engine cooldown timer
• Emergency stop
• Engine cycle crank
• Programmable cycle timer

5.5 inch Graphical Display

• Generator AC voltage
 3 phase (L-L&L-N)
 ± 0.25% Accuracy
• RPM & battery voltage
• Gen. AC current (per phase & avg)
• Generator frequency Communication
• Power metering (kW, kVA, kVAr, pf) • Accessory CAN data link
• Hour meters (kW-Hour, kVAr-Hour) • RS-485 annunciator data link
• Engine oil pressure (psi, kPa or bar) • RS-485 SCADA (Modbus RTU)
• Engine oil temperature (°C or °F) • Ethernet SCADA (Modbus TCP)
• Engine coolant temperature (°C or °F)
• Multiple language support
• Engine start & crank attempt counter
• Real time clock
EMCP 4.3 Features
Engine Protection
• Low oil pressure
• High coolant temp
• Low coolant level
• Fail to start
• Overspeed

.Other Features
• Programmable security levels
• Reduced power mode
• Programmable kW relay
Generator Protection • Tier 4 integration
• Over/under voltage • Cat Switchgear integration
• Over/under frequency • Status event log
• Generator phase sequence
• Over current (timed & inverse)
• Reverse power (real & reactive)
• Current balance
 EMCP 4.3 Input/Output
Digital Outputs
• 16 programmable outputs*
Analog Outputs
• 3 programmable outputs (4-20mA or ±10V)
• 2 programmable outputs (PWM)
Digital Inputs
• Emergency Stop
• Remote Start
• 12 programmable inputs*
Analog Inputs
• Oil pressure & water temperature
• 1 programmable input (±10V, PWM, current, or
resistive)
• Oil temp, fuel level, custom

* See specific package spec sheet for availability for

customer use
 EMCP 4.3 Control System
DEALER
Local Remote Remote
SERVICE TOOL Annunciator Annunciator Annunciator
“ET” CDVR
Generator Expansion
Engine Temps I/O
Temps

CAN2

RS-485 Annunciator Data Link

ADEM
RS-485 SCADA (Modbus RTU)
CAN1
Ethernet (Modbus TCP)
EMCP 4.3 Customer
Monitoring
Local Remote System
Synchronising Controls

EMCP4.4
EMCP 4.4 Features
Controls
• Auto/Start/Stop
• Engine cooldown timer
• Emergency stop
• Engine cycle crank
• Programmable cycle timer
• Paralleling
5.5 inch Graphical Display
• Generator AC voltage
 3 phase (L-L&L-N)
 ± 0.25% Accuracy
• RPM & battery voltage
• Gen. AC current (per phase & avg)
• Generator frequency
• Power metering (kW, kVA, kVAr, pf)
• Hour meters (kW-Hour, kVAr-Hour)
• Engine oil pressure (psi, kPa or bar) Communication
• Engine oil temperature (°C or °F) • Accessory CAN data link
• Engine coolant temperature (°C or °F) • RS-485 annunciator data link
• Multiple language support • RS-485 SCADA (Modbus RTU)
• Engine start & crank attempt counter or Cat Data Link (CDL)
• Real time clock • Ethernet SCADA (Modbus TCP)
 EMCP 4.4 – Paralleling Features
• Bus metering
• Dead bus arbitration
• Manual and automatic synchronization
• Real (kW) and reactive (kVAr) load sharing
• Load shed / load add
• Load sense / load demand
• MGDL (Ethernet) (with failsafe protection) or Hard-Wired paralleling
Utility G1 G2 G#
G1 G2 G# ~ ~ ...... ~
~ ~ ...... ~
CB1 CB2 CB#

CB1 CB2 CB# ATS

N E

Load Load

Multi-unit island mode Multi-unit standby

EMCP 4.4 Features
Engine Protection
• Low oil pressure
• High coolant temp
• Low coolant level
• Fail to start
• Overspeed

Other Features
• Programmable security levels
• Reduced power mode
• Programmable kW relay
Generator Protection • Tier 4 integration
• Over/under voltage • Cat Switchgear integration
• Over/under frequency • Status Event log
• Generator phase sequence • Embedded Webserver
• Over current (timed & inverse) • Supports dynamic gas blending
• Reverse kW, kVA • Transient Load Relief (TLR)
• Current balance
• Bus phase sequence
EMCP 4.2 Input/Output
Digital Outputs
• 17 programmable outputs*
Analog Outputs
• 3 programmable outputs (4-20mA or ±10V)
• 2 programmable outputs (PWM)
Digital Inputs
• Emergency Stop
• Remote Start
• 12 programmable inputs*
Analog Inputs
• Total of 4
• 2 for Oil pressure & water temperature for non-EUI
engines
• 2 programmable inputs (±10V, PWM, current, or
resistive)
• Oil temp, fuel level, custom

* See specific package spec sheet for availability for customer use
 EMCP 4.4 Control System
DEALER
Local Remote Remote
SERVICE TOOL Annunciator Annunciator Annunciator
“ET” CDVR
Generator Expansion
Engine Temps I/O
Temps

CAN2

RS-485 Annunciator Data Link

ADEM
RS-485 SCADA (Modbus RTU) or CDL
CAN1
Ethernet (Modbus TCP)
EMCP 4.4
Customer
Monitoring
Local Remote System
EMCP 4.4 Strengths and Considerations
Strengths
• Low install time
• Minimal complexity
Application Considerations
• No system HMI (MGDL overview only)
• Free PC Based remote monitoring
software available
• No utility paralleling*
• Basic load shed/add
• Low voltage only (less than 700 V)
• Challenging to upgrade on Global Design
(new controls packaging has easy retrofit kit
capability)
EMCP 4.4 (New Controls Packaging)
• Optional upgrades (factory)
• EMCP 4.4 includes circuit breaker open/close pushbuttons
• EMCP 4.4 does not require a factory installed circuit breaker
 Circuit breaker required for operation
 Retrofit Kits also available

EMCP 4.4
EMCP 4.4
EMCP 4.4 Paralleling Method General Comparisons
• Hardwired Paralleling
• Original Offering
• Individual Wires – easier to troubleshoot
• Reverse Compatibility with existing Woodward Load Sharing Lines and XQ
Modules
• Parallel up to 8 Gensets
• Multiple Genset Data Link (MGDL)
• Ethernet based
• Increased capability and Information
• Decreased setup and tuning steps required
• Parallel up to 16 Gensets
• Improved Load Add (Feeder Breaker) and LSLD
• Provides Failsafe Modes of Operation for DBA, LSLD, and Load Sharing
during a loss of communications
EMCP 4.4 MGDL: Simplified Wiring
Hardwired (HW) 10 wire MGDL Ethernet Connection
Interconnection and Switch

Switch
Ethernet Cable
EMCP 4.4 MGDL Overview Screen
“My unit” indicator

Indicates > 8 units

Unit %kW
(of Rated Real Power) ?
Solid – Mature communication
Reverse Video – Immature communication
Volts & Hz Question Mark – Loss of communication
Within Limits

Circuit Breaker Status:

Live Bus (fill) Open, Closed, Locked Out, Unknown (FID)
Dead bus (blank) (US and International Symbols)

System kW Hot key to view

(Real Power) additional units
( > 8 units)
System %kW (Real Power)
EMCP 4.4

1MW 1MW 1MW

Utility
EMCP 4.4

1MW 1MW 1MW

Genset mounted
EO breakers

Distribution
Switchgear
Utility Utility Utility by others

Priority Priority Priority

Level 1 Level 2 Level 3
Synchronising Controls

3rd Party Controllers

Why?
• Integrate With Existing Installation
• Common Fleet
• Customer Preference
• Additional Features
• Integrated Utility Synchronising and Load Sharing
• Dead Bus Synchronising
• Enhanced Remote Access
• Customisable Logic
Woodward - Easygen
• Automatic Synchronisation
& Load Sharing
• Up to 32 gensets
• 3 breaker control in one
controller
Comap - IntelliGen
• Automatic Synchronisation
& Load Sharing
• Up to 32 gensets
• Colour Display
• 5.7”,
• “WebSupervisor”
Dief – AGC4
• Automatic Synchronisation
& Load Sharing
• Up to 16 gensets / group
• Up to 16 groups
synchronised together
System Integration
PLC/SCADA Options
Agenda
• Applications
• PLC Options
• I/O
• Networks
• SCADA / HMI
• Communication Protocols
PLC based Control Systems
• Complex Control Philosophies
• System Integration
• Modular system
• can be scaled to accommodate any application
 Applications
Mains1 Mains 2 Mains 3 Mains 4

• Multiple Utility Control

• Multiple Generator Groups
MB1 MB2 MB3 MB4

• Bus-Coupler Control
FB3 FB4

AMF Applications
FB1 FB2
•
• Island/Utility Parallel
GFB1 GFB2 GFB3 GFB4

• Peak Lopping (Short Term Utility Paralleling)

• Peak Shaving (Long Term Utility Paralleling)
GB1 GB2 GB3 GB4 GB5 GB6 GB7 GB8

G1 G2 G3 G4 G5 G6 G7 G8
 Applications
• Building load management/system control
• Load Optimisation
• Fully configurable from SCADA screen
• Each breaker assigned a priority level (0 to 999)
• Mains/Generator maximum priority levels
• Predictive load steps
• N + x (e.g. N+1, N+2, etc.,)
 PLC Options
• Single PLC
• Flexible
• Scalable
• Dual ‘Cold’ Standby PLCs
• Increased reliability
• Typical 250ms to 1 sec switchover POWER
Logix5555TM

RUN

BAT

RUN REM
I/O

RS232

OK

PROG
ControlNET

A#01

CHA CHB OK
Redundancy Module

PRIM

PRI COM OK

• Dual ‘Hot’ Standby PLCs

A-B
Quality
Allen-Bradley

• Industry leading reliability (e.g. SIL2)

• Bumpless switchover A-B
Quality
Allen-Bradley
POWER
Logix5555 TM

RUN

BAT

RUN REM
I/O

RS232

OK

PROG
A#02
ControlNET

CHA CHB OK
Redundancy Module

SYNC

PRI COM OK
 I/O
• Local
• Distributed I/O
• via Ethernet
• Reduces installation wiring
• Redundant I/O
• Dual, Triplex, etc.,
• Increased reliability
 Networks
• Standard Ethernet and
TCP/IP
• Flexible implementation
• Star/Line Topology
• Simple low cost installation
• Ring Topology
• Increased system resilience
• Range
• 100 m between devices for
copper twisted-pair wiring
• Fibre cabling permits longer
distances (Up to 2kM)
 SCADA/HMI
• SCADA Displays
• Project specific screens
• Single Interface for system
overview & Control
• Data Logging
• Alarm/Event Logging
• Password protection

• HMI Displays
• Local generator display
SCADA/HMI
SCADA/HMI
 Communication Protocols
• Modbus
• Profibus
• Canbus
• DeviceNet
• ControlNet
• BacNet
• EtherNet