056-045 PLC as load control Issue 4 – A.D.

Manton








Using a PLC as a load demand controller


• DESCRIPTION

As flexible as DSE modules are, inevitably there are times when the module’s functions do not satisfy the
requirements of the customer specification.

One example of this is a load control system whereby the set’s running priority is automatically changed,
depending upon the size of the load. For instance, if the load is xkW, make set 1 priority, if the load is ykW,
make set 2 priority etc.

The simplest and most cost effective way to achieve this is by using a small PLC, with modbus master
capability. The PLC can be used to read kW load levels from all connected generator control modules using
RS485 modbus commands. The PLC can then decide which priority the sets should be, changing their
priority, again with modbus commands. Finally, starting and stopping signals can be sent to the controller,
again using modbus commands. Using a PLC in this way, no additional inputs or outputs are required on
the PLC as all monitoring and control is performed using the modbus data link.

Example.

Read the Total kW from each of the generator controllers. Add this up.
Based upon load levels, change Run Priority of the sets.
As required, send System control keys to the DSE controllers for Telemetry Remote Start if in Auto mode or Cancel
Telemetry Remote Start if in Auto mode. If required you can also send a control key to place the module into Auto
mode if it isn’t already.














Continued overleaf...



056-045 PLC as load control Issue 4 – A.D.Manton

• Modbus

The DSE Gencomm Modbus Register Mapping specification document is obtainable from DSE upon request by email
to support@deepseaplc.com. For convenience, some of the most important registers are listed below.

o Instrumentation and load share values

Description Modbus register
(decimal)
Type `
Generator Total Watts 1536 32 bit signed Read only
Set priority 35104 16 bit unsigned Read/write
Load Level Setting kW
(for fixed export)
35109 16 bit unsigned Read/write
Load Level Setting kVAr
(for fixed export)
35111 16 bit unsigned Read/write
Bus / mains mode
(for fixed export)
35112 16 bit unsigned Read/write


o Control

Control is performed by sending System Control Keys to the module, and also sending the bitwise opposite
(or one’s compliment) of the control key to another register ‘in the same write operation’ for security.

To modbus register 4104 (decimal) write the system control key as below
To modbus register 4105 (decimal) write the compliment of the system control key as below

Both of these registers MUST be written to the controller at the SAME TIME using the SAME MODBUS
WRITE COMMAND.

Function System Control Key Ones compliment of control
key (65535-control key)
Select STOP mode 35700 29835
Select AUTO mode 35701 29834
Telemetry start if in auto mode 35732 29803
Cancel telemetry start if in auto mode 35733 29802

More details of Gencomm Control Keys are contained in DSE Training Document 056-051 Gencomm Control Keys

• Connections

DSE8600 series have both RS232 and RS485 ports available for simultaneous use. Ensure the port you
are using (recommended RS485) is configured correctly.
Ensure you are using the RS485 version of the DSE5500 series controller or if you are using the DSE7500
series, ensure the RS485 port has been selected in the module configuration.
Connect the controllers to the PLC using industry standard RS485 cabling. DSE recommend and supply
BELDEN 9841 cable for RS485 use (DSE part number 016-030)
Remember that termination resistors must be correctly fitted and that the cable length must not exceed
1.2km (For cables other than Belden 9841, the maximum length may be different, depending upon cable
specifications.
Use the 8600 Config Suite (for 8600 series), Link7000 software (for 7500 series) or Link5000 (for 5500
series), to set the baud rate and slave address of the controller to match your PLC program.

For further details, refer to the DSE Gencomm document and the module’s operator manual
/ configuration software manual.