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KUHSE Operating Instructions

TA71SXXE.01

Control Unit for Gen. Power Sets July 1996


AUTOMATIC STAND-BY AND PEAK-LOAD CONTROL
Type: KEA 071-SPL (REPLACES 1994 EDITION)

GENERAL DESCRIPTION AND APPLICATION

Description is valid for Program No. 71-SPL, ∗ Sensing of mains voltage restoration, synchro-
version 010 or higher. nized overlap re-connection to mains supply
- Subject to be changed. - and
∗ Cooling-down/shut-down of generator set.
The Automatic unit KEA 071-SPL is designed to
The software for peak-load operation is designed
control stand-by and peak-load generating sets.
for:
Optionally, automatic synchronizer and automatic
power control may be integrated. Functions of out- ∗ Starting of prime mover on demand and syn-
put relays and the relevant parameters are to be chronizing the generator to mains voltage
set by using a lap-top. In position AUTOMATIC, re- ∗ Power control of generator set
connections to mains supply, and in position ∗ Reducing the generator output, when peak-load
TRIAL, change-overs from mains to generator operation shall be ceased
supply and vice-versa are executed with over-
lapped synchronizing, without any interruption. To monitor the assembly and the generator set,
the Automatic unit is fitted with following facilities:
The software for stand-by operation covers: 3-phase voltage sensors, for mains and generator,
∗ Mains voltage failure sensing monitoring under- and overvoltage, under- and
∗ Control of preliminary start conditions overfrequency, and asymmetry
14 externally connected fault signals
∗ Starting of prime mover on demand and
4 internally connected fault signals each, for mains
change-over from mains to generator supply
and generator voltage
∗ Frequency regulation for isolated generator set
(DC) battery voltage sensor (not applicable, when
operation
program for sliding power value control, under
∗ Generator set monitoring and protection peak-load conditions, is installed)
TA71SXXE.01 -2- 07 / 96

CAUTION !
This KEA unit shall be used only for purposes as announced in the written description
Installation and commissioning of equipment shall be executed by qualified persons only
Applicable rules, especially technical standards, as IEC or DIN VDE, have to be met strictly
On setting the parameters, it has to be watched, that hazards to persons or equipment are abso-
lutely excluded

CONTENTS

Design Page 3 Reverse power Page 11


Internal signals of volt. sensing Page
Interconnections Page 4
11
Operating and indication elements Page 4
Standard connections & programs Page 12
Operations and functions Page 5 Start sequence Page 12
Selector OFF/RESET Page 5 Operate or shut-down solenoid Page 12
Selector HAND Page 5 Run-up detection Page 12
Selector AUTOMATIC Page 6 Genset’s frequency control Page 13
Selector TRIAL Page 6 Peak-load supply Page 13
Push-button START Page 7 Additional signal contacts Page 13
Push-button LAMPS TEST Page 7 Emergency stop / emergency off Page 13
Push-button ALARM OFF Page 7
Integrated active power control
Operate and fault indications Page 7 (Optionally) Page 14
Controls on Page 7
Integrated automatic synchronizer
Automatic device locked Page 7
(Optionally) Page 15
Start indication Page 7
Overcrank / trouble Page 8 Connections of relay unit RZ 071-D Page 15
Mimic diagram /voltage sensing Page 8 Connections of analogue unit Page
17
Fault signals Page 9
Overspeed Page 10 Trouble shooting Page 18
Battery undervoltage Page 10 Parametering Page 19
Fault signals No. 13 & 14 Page 10
Mains breaker failure / tripped Page 10 Technical data Page 23
Generator overcurrent / Purchase ordering numbers Page 23
Gen. CB tripped Page 11
No engine set shut-down Page 11 Dimensions / Connection diagram Page 24
Synchronization failure Page 11
TA71SXXE.01 -3- 07 / 96

DESIGN

The components:
The Relay Unit RZ 071-D includes, besides others:
∗ Automatic Generator set Control Unit
KEA 071-SPL ∗ 10 relays, contacts rated for 6 A / 230 V ∼ or
∗ Relay Unit RZ 071-D, 30 V =, seven of these are suitable for parame-
∗ Relay Unit RZ 071-E, tering;
∗ Plug-in Cable Connection Set, ∗ 2 relays, contacts rated for 20 A / 30 V =, one of
these is suitable for parametering;
are needed to control stand-by and peak-load ∗ Multi-core plug-in connectors (Connection
generator sets automatically. means to control unit KEA 071-SPL and to
RZ071-E).
The Control Unit KEA 071-SPL is provided for
flush mounting into control board's front, the Relay The Relay Unit RZ 071-E contains:
Units RZ 071-D and RZ 071-E are to be fixed on
the mounting board inside the cubicle. ∗ 14 coupling relays, which are suitable for pa-
rametering;
Design of Control Unit KEA 071-SPL: ∗ 1 output relays for synchronizing pulse.

∗ Flush-mounting unit The automatic control unit KEA 071-SPL includes


∗ Protection degree (when installed): IP 44 an optical fiber connector, which permits data ex-
∗ Very compact design change with an optionally connected main control
∗ Circuitry in SMD mode station (in some cases, a protocol transducer will
∗ Removable label strips for fault indicating and be needed). When inserting an extra module, op-
operating push-button elements erating and fault conditions may be recorded.

Design of Relay Units RZ 071-D and RZ 071-E: Furthermore, the automatic control unit could be
parametered via optical fiber connector by a PC or
∗ printed circuit board flat unit, for fixing on laptop unit or, when connected to a telephone net-
mounting rail work, via MODEM. Thus, the following adjustments
∗ with snap-in fasteners for mounting rail in ac- or indications (locked by pass-word protection) can
cordance with DIN EN 50 022 be performed:
∗ Protection degree IP 00
∗ Coding the fault signals for
The Relay Units RZ 071-D and RZ 071-E serve as ∗ - alarm only or for shut-down conditions,
interface modules between control functions of ∗ - alarm sensing for open or closed circuits;
automatic unit KEA 071-SPL and switchgear as- ∗ - delayed or undelayed alarm conditions;
sembly. They have provisions to be connected to ∗ - alarms with or without tripping the generator
circuit
∗ DC Voltage supply from battery (changeable ∗ breaker.
from 12 V to 24 V) ∗ Adjustment of response values for voltage and
∗ Mains and generator circuit-breakers (or con- frequency sensing circuits and of values for de-
tactors) lay and running times;
∗ Cranking and shut-down means of prime mover ∗ Indicating of actual position of connected signal
∗ Necessary control relays contacts;
∗ Up to 14 signal and fault circuits ∗ Indication of actual voltage, frequency and
∗ Voltage supply from charging dynamo (Input is speed values and time settings.
fitted with automatic pre-excitation means for
dynamo)
TA71SXXE.01 -4- 07 / 96

INTERCONNECTION

IMPORTANT NOTE: to be watched strictly; otherwise, some special


The electrical connecting of control units electronic components could be damaged!
KEA 071 and RZ 071 are to be made by experi-
enced experts only! The DC coils of relays, contactors, and of all other
DC actuators shall be bridged by suppresser di-
The Automatic Generator set Control Unit odes or by other effective anti-interference protec-
KEA 071-SPL has to be connected with Relay Unit tions. These measurements shall be executed also
RZ 071-D via plug-in connectors by means of the for relays connected to potential-free output con-
attached multi-core cables. tacts!

The following signal wires have to be connected to Due to the fact, that a couple of relays may be
the Automatic Unit KEA 071-SPL directly: specially predetermined for several functions, the
printed status report, supplied with Automatic Unit
∗ Mains and generator voltage KEA 071-SPL, is to be taken as valid only.
∗ Battery voltage (in case the internal battery
Please note, that in case of a later replacement
voltage sensor shall be used)
supply, only those modifications or parameters are
∗ Measuring output of actual generator power
incorporated, on which we received information.
∗ Measuring output of speed sensor (in case of
using a tacho voltage generator or a pick-up) For a general connection diagram, please refer to
page 25.
The supply voltage from battery, and all further
signal wires have to be connected to the Relay
In case of disconnecting the battery (for instance to
Units RZ 071-D and RZ 071-E.
replace the battery), prior to this, the battery
charger has to be switched off!
The battery voltage input is fitted with a false con-
nection barrier, however, the correct polarity has

OPERATING AND INDICATING ELEMENTS

Indication lights Indication lights for fault


for basic functions signals (according to order) Indication lights for
voltage and frequency
monitoring

Indication Push-button „ON (I)“


lights for for mains / generator
fault signals
(according
to order) Push-button „OFF (0)“
for mains / generator

Indication lights for


signal „circuit closed“

Push-button selector Push-buttons


TA71SXXE.01 -5- 07 / 96

OPERATION AND FUNCTIONS

The relevant indicating and operating elements nals of the relay unit RZ 071-D (For example, by
are assembled, easy to survey, on the front plate connecting a key-operated control switch); so an
of the Automatic Unit KEA 071-SPL. The opera- unintentional or unacceptable change of a de-
tional modes are to be selected by means of four cided selection will be avoided.
push-buttons, with integrated LEDs, showing the
actual selected position. By push-button selector, the following modes of
operation are to be selected:
Activating the push-button selection may be
locked- out electrically by a wired jumper to termi-

OPERATIONAL MODE: OFF


On connecting the automatic unit to battery volt- ∗ Switching-off of all indicated fault signals (ex-
age, this operational mode position will be pre- cept fault signals No. 13 and 14, if external
selected automatically (Reset function), to prevent contacts should be still closed);
the generator set from starting unintentionally. ∗ Reset of automatic unit, if locked out (provided,
the external EMERGENCY OFF contact is not
On switching over from any other operational closed).
mode, the following will be initiated:
In case, mains voltage should be available, the
∗ Shut-down of generator set (if running); mains supply (i.e. mains circuit-breaker or contac-
tor) will be switched on in this selector position.

OPERATIONAL MODE: HAND


On selecting this operational mode, a relay, which pressing the „Generator OFF“ (0) push-button, the
is configured for the function „Auxiliary Drives generator circuit breaker will be opened, but the
ON“, will be energized at once; the LED „START mains circuit breaker will not be closed. Re-
INDICATION“ will show flashing light. There has connection to mains supply has to be made
to be a response signal, when engine start pre- manually.
paratory conditions are achieved. (Including, for
instance: GAS LEAK PROOF TEST ENDED, All change-over movements are executed without
WASTE GAS FLAP OPEN, LUB.-OIL PRES- synchronizing, that means, with interruption in
SURE AVAILABLE.) After that, the LED „START supply.
INDICATION“ will change to steady light, without
engine running. If there is no requirement for any Should, in this case, a fault signal with shut-down
start preparatory conditions, a fixed jumper from function occur - or, for instance, the fault signal
L(-) potential to the input terminal for this signal GENERATOR OVERCURRENT -, the generator
(RZ 071-D) shall be connected. breaker will be tripped, but the mains breaker will
not be closed automatically. - On the other hand,
Now, the generator set may be started by press- no automatic change-over to generator supply will
ing the push-button START. take place, if mains voltage should fail, while the
generator set is running.
Under this operational mode, when pressing the
„Mains OFF“ push-button (O) in mimic diagram, The ON push-button will be inactive, if the corre-
the mains supply can be switched off (even when sponding supply voltage of the system, which
generator set is not running!); to re-close the should be switched on, is not within its pre-set
mains supply, the „Mains ON“ push-button (I) has values, or if the phase sequence of this system
to be pressed. should be incorrect.

Provided, voltage and frequency of generator are A remote start demand signal does not initiate an
within its rated value limits, the load may be automatic closing of the generator circuit breaker.
changed-over from mains to generator supply, by
pressing the „Generator ON“ (I) or „Mains OFF“ To stop the generator set, the push-button selec-
(0) push-button, arranged in the mimic diagram. tor is to be set to position OFF or (if no start de-
mand signal is available) to position AUTOMATIC.
To re-connect the load to mains supply, the
„Mains ON“ push-button (I) has to be pressed. On
TA71SXXE.01 -6- 07 / 96

OPERATIONAL MODE: AUTOMATIC


When mains voltage is available, the mains supply After mains voltage has restored to normal values
is connected to load and the generator set is in and re-connection delay has elapsed, the genera-
automatic stand-by mode. tor will be synchronized to mains voltage (pro-
vided, the automatic synchronizing is enabled to
The mains voltage will be measured and monitored operate); after synchronizing, the generator circuit
permanently. As soon as the values for voltage or breaker will be switched off.
frequency are no longer within the adjusted limits,
this condition will be indicated by the correspond- In case the synchronized change-over is not re-
ing LED (f<, f>, U<, U>), arranged in the mimic quired to operate (Terminal # 20 / Relay Unit
diagram. After response time of sensing unit has RZ 071-D), re-connection to mains supply will take
elapsed (configurable), the start sequence pro- place with a switching interval.
gram will be initiated.
To prevent the engine from a heat increase, the
The start sequence program may be initiated, generator set will run unloaded for the configured
when mains voltage fails or when the connected idle run time, and then it will be shut-down.
remote start contact is closed, but also optionally,
when mains voltage fails and the remote start con- The program also may be configured, that the start
tact is closed simultaneously. The latter function sequence will run when the mains breaker should
additionally has provisions for a start blocking. be tripped by fault. (For switchboards in accor-
dance with DIN VDE 0107 or DIN VDE 0108; oth-
On initiating an automatic start, a relay, which is erwise available on demand.) The tripping of mains
configured for the function „Auxiliary Drives ON“, breaker will be indicated by a fault signal.
will be energized at once; the LED „START INDI-
CATION“ will show flashing light. There has to be a After eliminating the fault, this indication has to be
response signal, when engine start preparatory cancelled by pressing the push-button ALARM
conditions are achieved. (Including, for instance: OFF. If the mains voltage is available, the re-con-
GAS LEAK PROOF TEST ENDED, WASTE GAS nection to mains supply will be executed, after the
FLAP OPEN, LUB.-OIL PRESSURE AVAILABLE.) pre-determined delay.
After that, the LED „START INDICATION“ will
change to steady light, without engine running. If Additionally, the start sequence program may be
there is no requirement for any start preparatory initiated by remote start demand signals for
conditions, a fixed jumper from L(-) potential to the ∗ generator set operation with load transfer and
input terminal for this signal (RZ 071-D) shall be ∗ generator set operation without load transfer.
connected.
On remote start demand with load transfer, the
Now, the start sequence program will run and generator set automatically will be started and
crank the engine. If the generator set should not synchronized to mains voltage, before mains cir-
start, even after complete cranking sequence pro- cuit breaker will be opened (provided, mains volt-
gram has elapsed, the fault signal OVERCRANK / age is available). When the remote start input is
TROUBLE will occur and the automatic unit will be opened again, the re-connection of load from gen-
locked out (Signal: AUTOMATIC DEVICE erator to mains supply also will be executed with a
LOCKED). synchronized change-over.

When the generator set, after running up, has The input for remote start demand without load
reached rated voltage and frequency, the mains transfer is needed, for instance, when fire fighting
breaker will be switched off and the generator pumps are connected. On activating this input, the
breaker will be closed, with a change-over interval generator set will be started, but the generator cir-
of approximately 2 s (time value configurable). cuit breaker will not be closed automatically, while,
in case of a mains voltage failure, the generator
set will supply the load automatically.

OPERATIONAL MODE: TRIAL


On selecting this operational mode, a relay, which When engine start preparatory conditions are
is configured for the function „Auxiliary Drives ON“, achieved, (conditions see under mode HAND), the
will be energized at once; the LED „START INDI- LED „START INDICATION“ will change to steady
CATION“ will show flashing light. light and the start sequence program will be initi-
ated.
TA71SXXE.01 -7- 07 / 96

As soon as, after start of generator set, voltage


and frequency of the generator are within the rated In case of mains failure during TRIAL operation,
value limits, the load may be changed-over to gen- the load automatically will be changed-over to
erator supply, by pressing the generator breaker generator supply. It is not possible now, during
ON (I) or the mains breakers OFF (O) push-button, mains voltage failure, to open the generator
which are arranged in the mimic diagram. To breaker by means of push-button.
change-over to mains supply, the generator
breaker OFF (O) or the mains breaker ON (I) To stop the generator set, the push-button selector
push-button has to be pressed. is to be set to position OFF or (if mains voltage is
available) to position AUTOMATIC.
Change-over takes place with an overlap synchro-
nizing or with an interruption, depending on signal
to terminal # 20 of relay unit RZ 071-D.

PUSH-BUTTON: START
Only when operational mode HAND is selected, procedure, this circuit has to be connected exter-
the starter motor can be energized and the engine nally.
can be cranked by pressing the push-button
START. If the automatic unit’s program is config- When another operational mode is selected or
ured for a gas engine, this program sequence will when generator set is running, the push-button is
run. Should a diesel engine need a pre-glowing not active.

PUSH-BUTTON: LAMPS TESTING


On pressing this push-button, the indicating LEDs To include in this test further signal lights, assem-
of KEA 071 front panel will be checked, without bled in switchboard cubicle, a relay of relay unit
initiating or suppressing an actual alarm signal. RZ 071-D has to be parametered and connected.

PUSH-BUTTON: ALARM OFF


By a pulse of this push-button, the audible signal After having eliminated the source of trouble, the
caused by a fault signal, will be silenced. visible signals may be switched off by pressing the
push-button once again.

OPERATE AND FAULT INDICATIONS

The left-hand part of KEA front panel contains, ar- relevant operating and fault events. The following
ranged in two verticals, LEDs for indicating the indications are provided as a basic fitting:

CONTROLS ON
After starting the generator set, this signal indi- The indication is switched off, as soon as the shut-
cates the activating of monitoring circuits, which down procedure is beginning.
are depending on generator sets run.

AUTOMATIC DEVICE LOCKED


This indication shows, that an (external) EMER- To reset the control unit, the push-button selector
GENCY STOP push-button has been pressed or has to be set to position OFF(RESET). Prior to
that a faulty condition has caused the generator this, the reason for trouble has to be eliminated, or
set to shut-down. The automatic control unit as the EMERGENCY STOP push-button has to be
well as the generator set is locked-out for any fur- unlocked.
ther starting attempt.

START INDICATION
This signal is lighting, if there is a starting demand,
processed by the control unit, or if the operational As long as there is no enable signal for starting,
mode HAND or TRIAL is selected. the LED is flashing. On start enable signal, the
TA71SXXE.01 -8- 07 / 96

LED changes to steady light. tion speed. Now, it is not possible, to actuate the
starter motor, not even manually.
The indication is switched off automatically, when
the generator set’s actual speed exceeds the igni-

OVERCRANK / TROUBLE
This signal is switched on, if any shut-down command emitted by the auto-
∗ the generator set has not started, even after the matic control unit (with signal AUTOMATIC
complete start sequence program has elapsed UNIT LOCKED),
(simultaneously with signal AUTOMATIC UNIT ∗ the generator set is still running even after
LOCKED), complete stop time has elapsed (without signal
∗ the generator set came to a standstill without AUTOMATIC UNIT LOCKED).

MIMIC DIAGRAM / VOLTAGE SENSORS

The mimic diagram symbolizes incoming mains ∗ Overfrequency: Response and disengage value
and generator supply, circuit breakers and bus-bar ∗ Limit values for asymmetry
system. Push-buttons are assembled for: ∗ Response delay values for U< and f<
∗ Response delay values for U> and f>
∗ Mains breaker ON (I) ∗ Disengage delay values
∗ Mains breaker Off (0) ∗ „Undervoltage“ with additional fault alarm signal
∗ Generator breaker ON (I) ∗ „Overvoltage“ with additional fault alarm signal
∗ Generator breaker Off (0) ∗ „Underfrequency“ with additional fault alarm
signal
The CLOSED position of circuit breakers is indi- ∗ „Overfrequency“ with additional fault alarm sig-
cated by green LEDs, arranged below the corre- nal
sponding push-buttons. The LEDs are flashing, as
long as the synchronizing is active. Each monitoring criterion of mains and generator
voltage sensors:
There are four red and two green LEDs each for
mains and generator voltage monitoring. They in- ∗ Undervoltage,
dicate normal conditions of each voltage system or
∗ Overvoltage,
the character of deviation from normal.
∗ Underfrequency, and
The LEDs of first line, from left to right, are indicat-
ing: ∗ Overfrequency,

is configurable in such a manner, that:


∗ Underfrequency (f<)
∗ Voltage / frequency within normal range
∗ the output signal is not effective;
∗ Overfrequency (f>)
∗ the corresponding LED operates as a static in-
dication for the voltage sensor output;
The second line of LEDs indicates:
∗ the voltage sensor output is connected to an
additional fault alarm.
∗ Undervoltage / incorrect phase sequence (U<)
∗ Voltage / frequency within normal range
Static LED indication only
∗ Overvoltage (U>)
The corresponding red LED is alight, when an en-
The signal UNDERVOLTAGE also will occur in abled monitoring detects a deviation from normal
case of wrong phase sequence or in case of a value. During response delay, the green LEDs re-
voltage vector asymmetry. main lighted, and they go out, when the delay has
elapsed. The function now will be processed inter-
For voltage monitoring, the following parameters nally.
may be entered:
When voltage or frequency values have recovered
∗ Undervoltage: Response and disengage value to pre-determined limits, the red LED goes out at
∗ Overvoltage: Response and disengage value once and a disengage delay time runs. The green
∗ Underfrequency: Response and disengage LEDs are flashing, and they will change to a
value steady light, when the delay time has elapsed. In-
TA71SXXE.01 -9- 07 / 96

ternally, now the voltage system is recognized as LED indication along with fault signal
„within normal limits“. When parametered for fault alarm signals in case
of deviations from normal voltage or frequency
The generator’s LEDs are out of order, when the values, the alarm will be given only after response
operational mode OFF is selected, or when no delay time has elapsed. The green LEDs go out
start demand signal is available during AUTO- and the red LEDs operate as normal fault signal
MATIC mode. LEDs for mains voltage system are indicators, that means, they are flashing in case of
operative permanently. a faulty condition, and the audible alarm will sound.
As usual for all other fault signals, this signal trig-
gers the general collective alarm output also.

FAULT SIGNALS

As a basic arrangement, the automatic control unit - with delayed (acc. idle run time) gen. breaker
KEA 071-SPL is fitted with facilities to process 22 tripping, followed by generator set shut-
single fault indicating circuits, 4 of which are pro- down after idle running.
vided for monitoring of mains and generator volt-
ages, 14 are freely determinable by the user. Basi- The eight signals, which are internally used to
cally, there are three groups of fault signal proc- monitor the mains and generator voltages, are:
essing:
∗ Mains undervoltage
1. Operation dependent fault signals (for exam- ∗ Mains overvoltage
ple LOW OIL PRESSURE) will be active only, ∗ Mains underfrequency
when the generator set was started and an ad- ∗ Mains overfrequency
ditional time lag has elapsed. Activation of ∗ Generator undervoltage
these monitoring circuits is indicated by LED ∗ Generator overvoltage
signal CONTROLS ON.
∗ Generator underfrequency
∗ Generator overfrequency
2. Operation independent fault signals (for ex-
ample BATTERY UNDERVOLTAGE) are per-
When using control contacts, the alarm will be re-
manently active, except in case the push-button
leased on contact closing (NO circuits) or on con-
selector is set to position OFF.
tact opening (NC circuits). With analog value in-
puts, the alarm condition is released, when the
3. The fault signals No. 13 and 14 are active, in-
pre-set limit values will be passed. Each alarm will
dependent of generator set’s operation and of
be indicated by the corresponding LED with flash-
selected operational mode. These monitoring
ing light and by audible alarm (for the configured
circuits are used for permanently needed alarm
duration).
information, even if the push-button selector
should be set to position OFF (for example
To silence the audible alarm, a pulse has to be
LEAKAGE). In position OFF, the audible signal
given by push-button ALARM OFF; otherwise, the
will not be energized, but this signal triggers the
alarm will be switched off automatically (when pa-
general collective alarm output also. Any other
rametered time has elapsed). On silencing the au-
operational mode (except OFF) causes usual
dible alarm, the LED signal changes to steady
processing of these fault signals.
light. Several alarms, which could occur in se-
quence, would repeatedly release the audible
alarm; each alarm is indicated by a separate LED.
The fault signal processing may be configured, de-
pending on the actual execution of circuitry, as fol-
In case of warning alarms, another pulse by push-
lows:
button ALARM OFF will cancel the visible signal,
provided, the matter of alarm has been eliminated.
∗ For signal contacts in NO (normally open) or in
NC (normally closed) circuits; In case of signals, which lead to a shut-down of
∗ Delayed or undelayed operation dependent generator set, any subsequent operation is locked
alarm; out by the automatic control unit. This condition is
∗ Signals effecting a warning only or an additional shown by the LED signal AUTOMATIC DEVICE
generator set shut-down; LOCKED. To reset the automatic control unit, after
∗ Additionally, for warning signals: having eliminated the faulty condition (unlocking of
- without generator breaker tripping; an external EMERGENCY STOP push-button in-
- with immediate generator breaker tripping; cluded), the push-button selector has to be set to
TA71SXXE.01 - 10 - 07 / 96

position OFF (RESET). Now it is possible, to select the fault signal occurs or in case of a failure of
again an operational mode. power supply to the automatic unit.

The fault signal indications from No 11 to No 14, Regularly, the signal circuits will be shop-adjusted
when operating in NC circuits, are additionally con- in accordance with customer’s requirements. Nev-
figurable to actuate separate output relays. As long ertheless, all values may be entered or varied
as the signal is not available, the corresponding re- later, using a PC or a laptop. (For detailed informa-
lay is energized. The relay is switched off, when tion, please refer to the special instructions for pa-
rametering and configurating.)

OVERSPEED
To watch the overspeed condition, the generator The input of relay unit RZ 071-D, corresponding
frequency, or the frequency of a separate speed with this signal, will be compared also. So it is
sensor (pick-up or tacho generator) has to be de- possible, to connect an additional overspeed con-
tected. tact (for example a mechanical speed switch) to
this input terminal.
When using the generator frequency, it is neces-
sary to configure the fault signal GENERATOR Each configured OVERSPEED alarm leads to a
UNDERVOLTAGE as a shut-down signal. This shut-down of engine set, even in case of parame-
procedure makes sure, that in case of loss of tering all signal circuits for warning only (This
generator voltage the engine set will be shut- could be, for example, when prepared for supply-
down. ing fire fighting pumps).

For these signal circuits, the following parameters When exceptionally the connected external speed
may be set: contact shall initiate the OVERSPEED signal, but
also cause a shut-down when supplying fire fight-
∗ Limit speed for response; ing pumps, the internal signal has to be config-
∗ Disengaging value; ured to the corresponding fault signal indication
∗ No. of fault signal indication, which shall be No. The response speed values, however, have
coupled. to be configured in a way, that they will not be ex-
ceeded.

BATTERY UNDERVOLTAGE
This warning signal has to be parametered as be- ured upon request (not applicable, when program
ing active, independent of engine run. for sliding power value control, under peak-load
conditions, is installed). The following values are
To monitor this signal properly, the voltage supply configurable:
for automatic control unit KEA 071-SPL has to be
connected to another source than the monitored ∗ Response value,
battery (see National Standard ∗ Disengage value,
DIN VDE 0108/10.89, Part 1, Section 6.4.4.5, or ∗ Delay time,
comparable International Rules). ∗ No. of fault signal indication, which shall be
coupled.
This may be (as for example in large installations)
a common control potential, supplied by several A separate relay may be configured to the voltage
existing batteries, which are uncoupled by diodes. monitor output (NC circuit), effecting an NC alarm
signal transmitting, even in OFF mode.
For monitoring the battery voltage, additionally an
integrated battery voltage sensor may be config-

FAULT SIGNALS No. 13 & 14


The signal inputs No. 13 and 14 are capable to be Additionally, these signals are active also (but
retarded from 0 to 250 s. This means, the con- without audible alarm), when mode selector is in
cerned switching contact has to remain at least for OFF position. This feature could be necessary,
the pre-set time in the alarming position, before the when tank overfilling or leakage shall be observed
signal will be monitored. at any time.

INTERNAL SIGNAL: MAINS CIRCUIT BREAKER FAILURE


TA71SXXE.01 - 11 - 07 / 96

This fault signal is provided to indicate, that mains This signal is processed internally, when, after
breaker has opened without receiving a tripping emitting a closing pulse for circuit breaker (or con-
signal from automatic control unit (for example, tactor), the response signal for breaker position
when tripped by a circuit breaker assembled over- „CLOSED“ is not available within a certain time.
current release). To configure this signal circuit The pulse time for a contactor or breaker closing
(necessary to meet the requirements of National command therefore has to be parametered to a
Standards DIN VDE 0107 or DIN VDE 0108), a reasonable time (for example, 2 s).
valid signal indication number has to be entered.
The signal is additionally initiating the automatic The corresponding input of relay unit RZ 071-D,
start sequence program. The generator set will however, will be also active. This input could be
supply the load, as in case of mains voltage failure. used, for example, to connect a control contact of
an additional overcurrent relay, which can operate
in a logical OR function.

INTERNAL SIGNAL: GENERATOR CIRCUIT BREAKER FAILURE


This fault signal is provided to indicate, that gen- tactor), the response signal for breaker position
erator breaker has opened without receiving a „CLOSED“ is not available within a certain time.
tripping signal from automatic control unit (for ex- The pulse time for a contactor or breaker closing
ample, when tripped by a circuit breaker assem- command therefore has to be parametered to a
bled overcurrent release). To configure this signal reasonable time (for example, 2 s).
circuit, a valid signal indication number has to be
entered. This fault signal has to be configured for The corresponding input of relay unit RZ 071-D,
WARNING / SHUT-DOWN. however, will be also active. This input could be
used, for example, to connect a control contact of
This signal is processed internally, when, after an additional overcurrent relay, which can operate
emitting a closing pulse for circuit breaker (or con- in a logical OR function.

INTERNAL SIGNAL: NO ENGINE SHUT-DOWN


When the ENGINE RUNNING signal is still avail- ple, when a burned shut-down solenoid or a defec-
able, even after shut-down time has elapsed, the tive gas valve would prevent the engine from stop-
fault signal indication „OVERCRANK / TROUBLE“ ping.
will be initiated. This alarm would occur, for exam-

INTERNAL SIGNAL: SYNCHRONIZATION FAILURE


On the event of activating the automatic synchro- For this signal indication, the following parameters
nizer, a timer will be started. When the configured may be entered:
time has elapsed, the fault signal indication „SYN- ∗ Delay time for alarm;
CHRONIZATION FAILURE“ occurs. ∗ No. of fault signal indication, which shall be
coupled.

INTERNAL SIGNAL: REVERSE POWER


In case of a defective engine, when running in par- ∗ Delay time for alarm;
allel, the generator breaker has to be switched off. ∗ No. of fault signal indication, which shall be
An engine’s malfunction will cause a reverse active coupled.
power, verified by generator active power trans-
ducer, connected to measuring input terminal 8. The active power transducer shall supply an output
signal of:
For signal indication „REVERSE POWER“, the fol-
lowing parameters may be entered: 0 / 4 / 20 mA = -25 / 0 / +100 %
of generator output.
∗ Reverse power response value;

INTERNAL SIGNALS OF VOLTAGE MONITORING


Deviations of normal frequency or voltage values elapsed. The green LEDs go out and the red LEDs
are allowed to be indicated as fault signals. When operate as normal fault signal indicators, that
parametered for fault alarm signals, the alarm will means, they are flashing in case of a faulty condi-
be given only after response delay time has tion, and the audible alarm will sound. As usual for
TA71SXXE.01 - 12 - 07 / 96

all other fault signals, this signal triggers the gen- ∗ Signal with or without generator breaker trip-
eral collective alarm output also. ping.

When voltage or frequency deviations are config- A fault signal indication is not influencing the volt-
ured as fault signal indications, the following pa- age monitoring; that means for instance, the warn-
rameters (as usual for other signals) have to be ing indication „GENERATOR UNDERFRE-
entered: QUENCY“, once initiated, will not be cancelled,
when frequency has returned to normal. However,
∗ Delayed or undelayed signaling; the correct frequency will be known by the auto-
∗ Warning alarm only or shut-down; matic unit’s program.

STANDARD CONNECTIONS / PROGRAM SEQUENCES

The normal models of KUHSE Automatic Control Nevertheless, all parameters are changeable or
Units KEA 071-SPL are shop-configured as normal may be entered additionally, even after installation
in accordance with parameter list (see page 19), of switchboard. To realize this, a PC or laptop has
unless otherwise specified according to customer’s to be connected to the assembled optical fiber
orders. connector. For more details, please refer to special
instruction for coding and adjusting.

START PROGRAM SEQUENCE


The program is shop-configured for diesel or for ∗ Delay time for „CONTROLS ON“;
gas engine, according to order requirements. ∗ Delay for circuit breaker OFF;
∗ Idle running time;
The start sequence for gas engines is the follow- ∗ Shut-down time;
ing: ∗ Number of cranking attempts;
∗ Starter motor ON; ∗ Speed detecting by tacho generator;
∗ (2 s after exceeding ignition speed:) Ignition ∗ Speed detecting by pick-up;
ON; ∗ RUNNING signal via charging dynamo („D+“);
∗ (2 s after ignition ON:) Gas valve OPENED; ∗ RUNNING signal by generator voltage;
∗ (In case of no start, another 7 s later:) Gas ∗ Pick-up / tacho generator frequency at rated
valve CLOSED and speed;
∗ Starter motor OFF; ∗ Starter speed, disengage value;
∗ (after 6 s:) Ignition OFF; ∗ Ignition speed, disengage value;
∗ (1 s later:) Another start sequence. ∗ Rated speed, disengage value.
The following parameters are provided for a In case of using diesel engines, which require a
start / stop sequence: pre-glowing period to start, an external push-button
∗ Start delay; for pre-glowing has to be provided, operative in se-
∗ Cranking time; lected mode HAND. For an automatic start se-
∗ Time delay between „Starter ON“ and „Ignition quence, the pre-glowing time is configurable (Start
ON“; delay time).
∗ Time delay between „Ignition ON“ and gas flow;
∗ Interval;

OPERATE -, SHUT-DOWN SOLENOID; ELECTROMAGNETIC GAS VALVE


The normal way of configuring the shut-down sole- permitted, if switchboard and control circuitry have
noid is NO condition; that means, the solenoid will to meet the requirements of German Standard DIN
be energized (for an adjusted time) to shut-down VDE 0107!
the generator set. The solenoid remains energized,
until generator set has reached standstill position. In case of using gas engines, the relay -K1 is con-
figurable for the function GAS VALVE OPEN.
In case, the engine is fitted with an operate sole- When two relays are required to be installed in the
noid, which is de-energized to shut-down the gen- gas safety path, another relay may be configured
erator set, the control mode for relay -K1 (Relay in like manner.
Unit RZ 071-D) has to be changed. This is not
TA71SXXE.01 - 13 - 07 / 96

DETECTION OF ENGINE RUNNING CONDITION


The correct point of exceeding the engine’s ignition
speed for switching off the starter motor has to be In case of governing gas engines, it is absolutely
sensed doubtless. For this reason, the automatic necessary, to provide a pick-up, or a tacho genera-
control unit KEA 071-SPL is regularly fitted with tor with frequency signal output.
separate inputs for charging dynamo, tacho gen- The input for charger dynamo has provisions for an
erator and for pick-up connection. initial excitation of the dynamo, so AC charging
The wiring for pick-up or for tacho generator generators may be used also without problems.
connection has to be executed in shielded ca- The initial excitation will be switched off simultane-
bles. ously with starter motor.

For safety reasons, the program of automatic con-


The tumbler switch, arranged at the rear side of
trol unit KEA 071-SPL has facilities to detect the
automatic unit KEA 071-SPL, has to be set in ac-
generator voltage also; so, an unintended engag-
cordance with connected equipment:
ing of starter during engine run is avoided.
∗ Lever in left position ( ): Pick-up
∗ Lever in right position ( ): Tacho generator

FREQUENCY CONTROL DURING ISOLATED GENERATOR SET OPERATION


When the generator set substitutes the mains The following parameters are configurable:
power, the generator set’s frequency may be con-
trolled to a rated value, independent of actual load. ∗ Frequency maximum value;
Therefore, the engine shall have provisions for re- ∗ Frequency minimum value;
mote speed control, or an electronic governor, fit- ∗ Pulse length for governor;
ted with control input, has to be assembled. ∗ Interval between pulses.
The automatic unit emits adjusting pulses to the Please note, that the interval and pulse times for
engine’s governor, when frequency is not within frequency control are the same as for frequency
parametered limits. The interval between two matching during synchronizing.
pulses, for enabling the engine to react, is also
configurable.

PEAK LOAD SUPPLY


When operational mode AUTOMATIC is selected, 10% of rated load, before the generator breaker
the generator set will be started on a peak load will open.
demand signal. After normal running conditions
have been attained, the generator set will be syn- In case the internal output power control will not be
chronized to mains voltage. applied, there are control inputs and outputs pro-
vided to connect an external power control unit.
When running in parallel, the internal output power
control (optional assembly) will be ready to charge Mains voltage failures during peak load supply
the generator set. For a functional description of in- shall be monitored by special equipment, for ex-
ternal output power controller (optional assembly), ample by a KNAE 9408 unit. This device will trip
please refer to next page. the mains breaker directly, so the generator set
alone will continue to supply the load.
The configuring permits to run the generator set
with a (parametered) constant output, or to control When mains voltage has returned to normal condi-
the output power by an external signal (for exam- tions and after a re-connection delay, the genera-
ple, by a signal from a main control station), or by tor set will be synchronized to mains voltage.
a manually adjusted set value (for example, by When the peak load demand signal is available,
means of a separately arranged rheostat). the generator set again will run in parallel with
mains supply; if not, the generator breaker opens
When the peak load demand signal is cancelled, and the generator set will shut-down after idle run-
the generator set will be unloaded to approximately ning time has elapsed.

FURTHER SIGNAL CONTACTS


For further switchboard control applications (signal functions are shop-configured on demand, but the
lamp test, manual operations, or in like manner), function mode may be changed also later without
several relays are configurable. These special any problem.
TA71SXXE.01 - 14 - 07 / 96

nected to control outputs, shall have anti-


The declared current ratings of relay contacts interference protection!
shall not be exceeded! Each electric coil, con-

EMERGENCY STOP / EMERGENCY OFF (EXTERNAL)

The Relay Unit RZ 071-D is fitted with a terminal NOTICE: When installing the switchboard wiring,
No. 19, to connect EMERGENCY STOP push- an additionally wired direct connection to the en-
buttons. gine set's shut-down equipment shall be provided,
overriding the computer controlled EMERGENCY
Only one short pulse is needed to initiate the STOP function.
EMERGENCY STOP procedure. Independent of
actual operational mode, the following functions To perform a complete EMERGENCY OFF func-
will be activated: tion, not only the terminal No. 19 of Relay Unit
RZ 071 for EMERGENCY STOP has to be con-
∗ Tripping of generator breaker; nected, but it has to be made sure also, that the
∗ Shut-down of generator set; mains breaker will be tripped on receiving this
∗ Locking-out of control unit for any further start command.
attempt (Indication: AUTOMATIC DEVICE
LOCKED).

INTEGRATED OUTPUT POWER CONTROLLER (OPTIONALLY)

The output power controller (assembled optionally, This is important to be considered, when operating
on demand) is configurable to act as a constant as sliding power value controller. When connected
power value controller, or as a sliding power value to a main control station, the value of 100 % gen-
controller. The generator set, running in parallel erator output has to be calculated. The measuring
with mains, will be charged with parametered load input, of course, then shall not be used for monitor-
(constant power value controller), or with a load ing the battery voltage.
corresponding to the set value of measuring input,
terminal 7 (sliding power value controller). The The power controller is acting in a two-level mode.
power control system is active only, when opera- The following parameters may be entered:
tional mode AUTOMATIC or TRIAL is selected.
∗ Internal controller activated or not activated;
When the two-level action of power controller is not ∗ Constant power or sliding power value control;
activated, an external controller has to be pro- ∗ Measuring range of active power transducer;
vided. Suitable relays for connecting an external ∗ Rated power of generator set;
controller are configurable. ∗ Nominal power for constant power control;
∗ Hysteresis of power controller;
The actual generator output value has to be con-
∗ Response value for REVERSE POWER;
nected as active power transducer signal to meas-
∗ Alarm delay for REVERSE POWER;
uring terminal 8. The active power transducer shall
supply an output signal of 0 / 4 / 20 mA, corre- ∗ Fault signal for REVERSE POWER;
sponding to -25 / 0 / +100 % of generator output. ∗ Pulse duration for speed adjusting;
The signal range from 0 to 4 mA (according to -25 ∗ Intervals for generator loading;
to 0 % of generator output) is required to monitor ∗ Interval at final control value;
REVERSE POWER. ∗ Monitoring delay for generator unloading.

All installed measuring current loops shall be The generator set will be charged gradually, after
potential-free. having been coupled to run parallel with mains
supply. For a weak load transfer, the time value of
intervals for generator loading has to be chosen of
The output signal of 4 - 20 mA corresponds suitable duration.
with declared power value of measuring trans-
ducer, but not with a percentage of generator’s When the range limits of parametered output
output power. power once have been attained, another (shorter)
interval between adjusting pulses will become ef-
TA71SXXE.01 - 15 - 07 / 96

fective, so the controller will be capable to react


rapidly to a deviation from set value. On the event of activating the generator’s unload-
ing, a timer will be started. When the configured
On ending the peak load supply, the generator set time has elapsed, without any unloading, probably
will be unloaded gradually. When actual value falls the speed control circuit may be faulty, and the
below 10 % of generator rated output, the genera- generator breaker also will be tripped, independent
tor circuit breaker will be opened. At the same of actual load.
time, the input for signal UNLOADED will be moni- In case of performing an external power controller,
tored. In case a L(-) potential is available, the gen- the signal UNLOADED has to be led to relay unit
erator breaker also will be tripped immediately. input.

INTEGRATED AUTOMATIC SYNCHRONIZER (OPTIONALLY)

The internal automatic synchronizer (assembled time within a range of 40 to 140 ms (in steps of
optionally, on demand) is acting as a single- 20 ms). The recommended settings are:
channel device, on which the closing time of circuit
breaker is configurable. Because the measuring ∗ Difference frequency: 0.2 ... 0.3 Hz;
voltage is only single phase connected, for safety ∗ Difference voltage: 10 % of rated voltage.
reasons a check synchronizer should be installed,
as a second channel device. When operating generating sets with large rotating
masses, it is recommended to equip the automatic
When monitoring the duration of synchronizing synchronizer, type KSY 11.
procedure, a fault signal may be initiated on ex-
ceeding the time. It is configurable, whether the When activated, the automatic synchronizer will
change-over of load shall be executed with an in- check, whether the difference frequency is within
terruption, or the automatic synchronizing proce- the permitted limits or not. If not, an adequate
dure shall continue to act. pulse to the speed governor will be emitted, fol-
lowed by an interval, enabling the engine set to re-
The following parameters may be entered: act. During the interval, the synchronizing action is
restrained.
∗ Automatic synchronizer activated or not acti-
vated; When the difference frequency should be less than
∗ Permitted difference frequency; 0.08 Hz, an output signal for SPEEDING UP will
∗ Permitted difference voltage; be emitted.
∗ Closing time of circuit breaker (or contactor);
∗ Fault signal delay for SYNCHR. FAILURE; The difference voltage also will be checked. In
∗ No. of fault signal indication, which shall be case of deviations being out of permissible limits,
coupled; the synchronizing will be locked out.
∗ Pulse length for frequency matching;
∗ Interval between pulses. On full compliance of parameters, the breaker
closing pulse will be emitted with an advance time
The difference frequency is adjustable within a (which equals closing time) before the moment of
range of 0.1 to 0.4 Hz, and the breaker’s closing synchronism. The closing pulse has double length
of closing time.
TA71SXXE.01 - 16 - 07 / 96

CONNECTIONS OF RELAY UNIT RZ 071-D

The control switches, connected to terminals 1 to dividual printed status report is valid only for a
28, shall be connected to L(-) potential. Terminal definite automatic unit KEA 071-SPL.
29 is provided to be connected to terminal D+ of
charging dynamo. The relay unit contains features The declared current ratings of relay contacts shall
for an initial excitation of charging dynamo. not be exceeded! Each electric coil, connected to
control outputs, shall be fitted with suppresser di-
The functions of several relays may be different, odes (in case of DC coils) or shall have adequate
according to special configuring. Therefore, the in- anti-interference protection!

TERMINALS 1 - 14: FAULT SIGNAL INDICATIONS 1 - 14


These terminals are provided as inputs for fault for these signals are to be connected to L[-] poten-
signal circuits 1 to 14; the external control contacts tial.

TERMINAL 15: MAINS OFF


To indicate mains circuit breaker’s position, an The automatic unit KEA 071-SPL is fitted with an
auxiliary contact (NC, coupled to L[-] potential) of interlocking circuit, which prevents the generator
mains circuit breaker (or contactor) has to be con- circuit breaker from direct closing in case of con-
nected to terminal 15, as a response signal. nected mains supply.

TERMINAL 16: GENERATOR OFF


To indicate generator circuit breaker’s position, an The automatic unit KEA 071-SPL is fitted with an
auxiliary contact (NC, coupled to L[-] potential) of interlocking circuit, which prevents the mains cir-
generator circuit breaker (or contactor) has to be cuit breaker from direct closing in case of con-
connected to terminal 15, as a response signal. nected generator supply.

TERMINAL 17: BLOCKING OF MODE SELECTION


When an L[-] potential is connected to terminal 17, ample, by a key-operated switch, to avoid a
the selection of operational modes by push-buttons change of selected mode by unauthorized persons
will be blocked. This could be performed, for ex- or by error.

TERMINAL 18: REMOTE START DEMAND (WITH LOAD TRANSFER)


When an L[-] potential is connected to terminal 18 takes place with an overlap synchronizing, that
and when operational mode AUTOMATIC is se- means, without an interruption.
lected, the start of generator set will be initiated
and the load will be transferred from mains to gen- On disconnecting the signal to terminal 18, the
erator supply. The generator circuit breaker also generator circuit breaker will be tripped after re-
would be closed automatically, when the generator connection delay, and the generator set will be
set should be running under operational mode shut-down after idle running time, provided, there
TRIAL, or in mode AUTOMATIC, started by signal is no signal for remote START WITHOUT LOAD
REMOTE START (WITHOUT LOAD TRANSFER). TRANSFER available.
When mains voltage is available, the change-over

TERMINAL 19: EMERGENCY SHUT-DOWN


When an L[-] potential is connected to terminal 19, control unit, the operational mode selection has to
the generator set will shut-down immediately. The be set to position OFF. This is possible only, when
automatic control unit will be locked-out for any fur- there is no longer the L[-] potential at terminal 19;
ther starting attempt (indicated by signal AUTO- otherwise, the LED indication AUTOMATIC DE-
MATIC DEVICE LOCKED). To reset the automatic VICE LOCKED would remain lighted.

TERMINAL 20: OVERLAP SYNCHRONIZING ACTIVE


When an L[-] potential is connected to terminal 19, supply (in operational mode TRIAL) and the re-
the load transfer between mains and generator connection to mains supply (in operational mode
TA71SXXE.01 - 17 - 07 / 96

AUTOMATIC) will take place without interruption, When an L[-] potential is not available at terminal
by synchronized change-over. 19, the change-over between mains and generator
supply will take place with configured intervals.

TERMINAL 21: PEAK-LOAD DEMAND


When an L[-] potential is connected to terminal 21, On interrupting the peak-load demand signal, the
the generator set (in operational mode AUTO- generator set will be unloaded gradually; when the
MATIC) will be started and synchronized to mains output power falls below 10 % of rated power, the
voltage automatically. After that, the generator set generator breaker will be opened.
will be charged gradually, following a ramp charac-
teristic.

TERMINAL 22: GENERATOR SET UNLOADED


This input has to be used, when an external tor set. When the controller has caused the
power controller is connected. To activate this unloading of generator set, the input terminal 22
controller, certain relays of relay unit may be con- shall receive the accordant signal; to initiate the
figured accordingly, that the controller may receive opening of generator circuit breaker.
the signal to be activated or to unload the genera-

TERMINAL 23: WARNING FUNCTIONS OF FAULT SIGNALS


On connecting this input terminal 23 to L[-] poten- SPEED may be locked out from this procedure and
tial, all the fault sensing circuits are leading to will remain in shut-down mode. The signal OVER-
warning alarms only. But, using the parametering SPEED may be initiated internally or via connec-
program, on pressing key F5 and entering a valid tion to the corresponding input terminal.
key number, the signal circuit for sensing OVER-

TERMINAL 24: START ENABLE INPUT


Any start attempt, emitted manually or automati- No. 24 has to be connected.
cally, will be interlocked as long as there is no L[-]
potential connected to terminal No. 24. So, it is This function does not meet the requirements of
possible to incorporate relevant pre-start condi- the German Standards DIN VDE 0107 (5.4.11),
tions, before a signal to starter motor for cranking because a running engine set will not be shut-
will be given. In case this function is not down; this function provides means only to protect
needed, a wire jumper from L[-] to terminal the engine before start.

TERMINAL 25: REMOTE START (WITHOUT LOAD TRANSFER)


When operational mode AUTOMATIC is selected, on an additional signal to terminal 18. To open the
the generator set may be started by connecting L[-] generator breaker again, both of signals (25 and
potential to terminal 25, but the generator set will 18) must be cut.
run idle. The generator breaker will be closed only

TERMINAL 29: CHARGING DYNAMO (TERMINAL D+)


The charging dynamo, if any, has to be connected dynamo will cause the cranking motor to be
to this terminal. The dynamo receives the initial switched off.
excitation via this connection, and the L[+] signal of
TA71SXXE.01 - 18 - 07 / 96

CONNECTIONS OF ANALOG EQUIPMENT

TERMINAL STRIP -X 401


Junction 1: Current loop [+], measuring input 7 Junction 5: - see under „Junction 3“ -
Junction 2: Current loop [-], measuring input 7 Junction 6: Current loop [+], generator power
Junction 3: To be connected with 5, if measur- Junction 7: Current loop [-], generator power
ing input 7 is used for current Junction 8: Pick-up, pulse input
measuring Junction 9: Pick-up, screen (shielding)
Junction 4: Battery voltage L[+], when input 7 is Junction 10: Mass (ground) connection
used as battery voltage monitor

When measuring input 7 is used for battery voltage monitoring, the terminal points 3 and 5 of terminal
strip -X 401 shall not be bridged, because the burden would amount to 240 !
In this case, a jumper between the two terminals would destroy the measuring input!

TERMINAL STRIP -X 402


Junction 1: Conductor L1 of generator voltage Junction 3: Conductor L3 of generator voltage
Junction 2: Conductor L2 of generator voltage Junction 4: Neutral conductor of generator

TERMINAL STRIP -X 403


Junction 1: Conductor L1 of mains voltage Junction 4: Neutral conductor of mains
Junction 2: Conductor L1 of mains voltage Junction 5 Protection earth (ground)
Junction 3: Conductor L1 of mains voltage

TUMBLER SWITCH
The tumbler switch, arranged at the rear side of ∗ Lever in left position ( ): Pick-up
automatic unit KEA 071-SPL, under the protection ∗ Lever in right position ( ): Tacho generator
hood covering the analog equipment, has to be set
in accordance with connected unit:

TROUBLE SHOOTING

In case of malfunctions occurring during commis- is highly implausible, provided, an unsuitable


sioning or operation, origin of which are not handling can be excluded.
straight-away clear, at first all peripheral condi-
tions of the complete control system should be The following list shows a couple of mistake pos-
checked carefully. Considering the elevated grade sibilities, perhaps making it easier to search for
of integration of KUHSE automatic control unit’s malfunction causes.
circuitry, a failure or defect in the internal system

NO AUTOMATIC START ON REMOTE START DEMAND


∗ In case of flashing LED „START INDICATION“,
check, whether the START ENABLE signal is
available or not.

LED „START INDICATION“ REMAINS ALIGHT AFTER ENGINE START


∗ Check the relevant wires and signals coming ∗ Measure signal voltages of charging dynamo
from charging dynamo, tacho generator or (Terminal D+) or of tacho generator; when en-
pick-up sensor. gine is running, at terminal D+ the rated value
TA71SXXE.01 - 19 - 07 / 96

of voltage has to be measured (corresponding When measuring the tacho generator voltage,
to battery voltage). use oscilloscope or high-ohmic instrument
only!

GENERATOR CIRCUIT BREAKER OR CONTACTOR DOESN’T CLOSE


∗ When green LEDs are not lighting, check ac- erator voltage, check the phase sequence at
tual voltage and frequency of generator. When automatic unit’s input terminals.
signal „U<“ is indicated in spite of correct gen-

GENERATOR BREAKER IS CLOSED AND RE-OPENED IMMEDIATELY


∗ Check, if initial current of connected load is too (or contactor) and the corresponding control
high (Observe ammeters!). wiring. The auxiliary response signal contact
has to be open, when generator breaker is
∗ In case of enabled signal indication „GEN- closed.
ERATOR CB FAILURE“: Check auxiliary re-
sponse signal contact (NO) of generator CB

IRREGULAR FAULT SIGNAL „OVERSPEED“ (POSSIBLY AT ENGINE STAND-STILL)


∗ Observe, that measuring wires between tacho ∗ Verify, that switchboard equipment (for exam-
generator and automatic control unit KEA 071 ple, contactor coils) is sufficiently protected
in cubicle are installed in shielded cables. It against emitting high-voltage peaks, for in-
must be assured, that only one end of shield is stance by RC suppresser elements.
connected to L[-] potential, and no other con-
nection to L[-] exists.

IRREGULAR FAULT SIGNALS (GENERAL)


∗ Check, if configuration of program is complying
with signal circuit contact (If program is con- ∗ Inspect, that no signal line is broken (in case of
figured for NC circuit, the contact has to open, NC circuits) or short-circuits against L[-] exist
if configured for NO circuit, the contact has to (in case of NO circuits).
close in case of fault signal condition).

PERMANENT SIGNAL: AUTOM. DEVICE LOCKED (NO SELECTION POSSIBLE)


Verify, that ∗ that EMERGENCY STOP connection of Relay
∗ no (external) EMERGENCY STOP or EMER- Unit RZ 071-D was not connected by error.
GENCY OFF push-button is still unlocked after
having been pressed, and

If none of the malfunction cases, as described tives, or our Service Section. In every case, please
above, should correspond with the mentioned specify the unit’s serial number (from name plate
symptoms, or should none of the recommended of unit) or the KUHSE Delivery Order No., and de-
measurements lead to solve the problem, please scribe as clearly as possible the control unit’s ab-
contact one of our authorized Service representa- normal reaction.
TA71SXXE.01 - 20 - 07 / 96

PARAMETERING

The following table shows the standard shop-configura- On request, the parameters will be shop-adjusted. For
tion, which is executed in case of no special customer’s this purpose, please send a copy of the list below, with
requirements. However, all values may be entered or filled-in required values.
varied later, using a PC or a laptop. The label stripes of
fault signal indications may be printed with a PC write Other internal signal functions (for example „Push-button
program; the labels are easy to exchange. Values that selector OFF actuated“) are suitable to be parametered
are configurable are identified by squared brackets [ ]. on certain relays. In case of need, please contact our
sales department for further information.

START SEQUENCE PROGRAM


ENGINE IS FITTED WITH: [SHUT-DOWN SOLENOID] OPERATE SOLENOID ELECTROMAGN. GAS VALVE
START DELAY (PRE-GLOWING TIME) [2 sec] sec
CRANKING CYCLE TIME [7 sec] sec
CRANKING INTERVAL [7 sec] sec
NUMBER OF START ATTEMPTS 3
„CONTROLS ON“ DELAY [7 sec] sec
RE-CONNECTION DELAY [60 sec] sec
IDLE RUNNING TIME [180 sec] sec
SHUT-DOWN TIME [30 sec] sec
TIME BETWEEN „CRANKING“ ⇒ „IGNITION ON“ [2 sec] sec
TIME BETWEEN „IGNITION ON“ ⇒ „GAS VALVE OPEN“ [2 sec] sec

MAINS VOLTAGE MONITORING


MONITORED CRITERIA YES NO YES NO CODING RESPONSE / RESET VALUE RESPONSE / RESET VALUE
UNDERVOLTAGE [ ⌧] [185 / 205 V] / V
AS FAULT SIGNAL? [ ⌧]
OVERVOLTAGE [ ⌧] [264 / 250 V] / V
AS FAULT SIGNAL? [ ⌧]
UNDERFREQUENCY [ ⌧] [48 / 49 Hz] / H
z
AS FAULT SIGNAL? [ ⌧]
OVERFREQUENCY [ ⌧] [52.1 / 51 Hz] / H
z
AS FAULT SIGNAL? [ ⌧]
DELAY ON EXCEEDING: [4 sec] sec DELAY ON UNDERPASSING: [1 sec] sec

DISENGAGE DELAY: [4 sec] sec

GENERATOR VOLTAGE MONITORING


MONITORED CRITERIA YES NO YES NO CODING RESPONSE / RESET VALUE RESPONSE / RESET VALUE
UNDERVOLTAGE [ ⌧] [185 / 205 V] / V
AS FAULT SIGNAL? [ ⌧]
OVERVOLTAGE [ ⌧] [264 / 250 V] / V
AS FAULT SIGNAL? [ ⌧]
UNDERFREQUENCY [ ⌧] [48 / 49 Hz] / H
z
AS FAULT SIGNAL? [ ⌧]
OVERFREQUENCY [ ⌧] [52.1 / 51 Hz] / H
z
AS FAULT SIGNAL? [ ⌧]
DELAY ON EXCEEDING: [4 sec] sec DELAY ON UNDERPASSING: [1 sec] sec

RESET DELAY: [4 sec] sec


TA71SXXE.01 - 21 - 07 / 96

FAULT SIGNAL INDICATIONS


PARAMETER ITEM CODING

FAULT SIGNAL 1 [GENERATOR OVERCURRENT] [RUG0]

FAULT SIGNAL 2 [SHORT CIRCUIT] [RUS0]

FAULT SIGNAL 3 [LOW LUB.-OIL PRESSURE] [AVS0]

FAULT SIGNAL 4 [ENGINE OVERTEMPERATURE] [AVS0]

FAULT SIGNAL 5 [LACK OF FUEL] [AUG1]

FAULT SIGNAL 6 [OVERSPEED] [AUS0]

FAULT SIGNAL 7 [BATTERY UNDERVOLTAGE] [AUG1]

FAULT SIGNAL 8 [AUG1]

FAULT SIGNAL 9 [AUG1]

FAULT SIGNAL 10 [AUG1]

FAULT SIGNAL 11 [AUG1]

FAULT SIGNAL 12 [AUG1]

FAULT SIGNAL 13 [AUG1]

ACTIVATING DELAY OF FAULT SIGNAL 13 [0 sec] sec

FAULT SIGNAL 14 [AUG1]

ACTIVATING DELAY OF FAULT SIGNAL 14 [15 sec] sec

CODINGS: R= NORMALLY CLOSED U= UNDELAYED G= ALARM CONDITION 1= GENERATOR CB NOT TRIP-


PING
A= NORMALLY OPEN V= DELAYED S= SHUT-DOWN CONDITION 0= GENERATOR CB TRIPPING

INTERNAL FAULT SIGNALS


BATTERY UNDERVOLTAGE FOR INDICATION AT FAULT SIGNAL No.: [7]
OVERSPEED FOR INDICATION AT FAULT SIGNAL No.: [6]
GENERATOR BREAKER FAILURE FOR INDICATION AT FAULT SIGNAL No.: [1]
MAINS BREAKER FAILURE FOR INDICATION AT FAULT SIGNAL No.: [0]
GENERATOR REVERSE POWER FOR INDICATION AT FAULT SIGNAL No.: [0]
SYNCHRONIZATION FAILURE FOR INDICATION AT FAULT SIGNAL No.: [0]

SPEED DETECTING
SPEED DETECTING BY: [CHARGING DYNAMO] TACHO GENERATOR PICK-UP GENERATOR FREQUENCY
RATED SPEED (RPM) OF ENGINE: [1500 min-1] min-1
TACHO FREQUCY. AT RATED [50 Hz] Hz
SPEED:
PICK-UP FREQUCY.AT RATED SPEED: Hz

SPEED SET VALUES


STARTING SPEED; RESPONSE VALUE / DISENGAGE VALUE 1) [80 / 70 min-1] / min-1
1 -1
FIRING SPEED; RESPONSE VALUE / DISENGAGE VALUE ) [300 / 250 min ] / min-1
RATED SPEED; RESPONSE VALUE / DISENGAGE VALUE [1500 / 1470 min-1] / min-1
2 -1
OVERSPEED ); RESPONSE VALUE / DISENGAGE VALUE [1650 / 1450 min ] / min-1
1
) Required only , when start sequence program is configured to control gas engines (Tacho generator or pick-up required!).
2
) If no tacho generator or pick-up is available, the speed will be detected out of generator frequency. In this case, GENERATOR UNDERVOLTAGE has
to
be configured as shut-down signal.
TA71SXXE.01 - 22 - 07 / 96

BATTERY VOLTAGE MONITORING


IMPORTANT NOTE: INTERNAL BATTERY MONITORING PROVIDES, THAT PROGRAM FOR SLIDING POWER VALUE CONTROL (UNDER
PEAK-LOAD CONDITION) IS NOT CONFIGURED!
RESPONSE VALUE 1) [12.6 V] [25.2 V] V RESET VALUE [12.9 V] [25.7 V] V

RESET DELAY: [60 sec] sec


1
) Acc. to DIN VDE 0107 , -0108: Voltages less than 2.1 V/Cell (Lead-acid batteries) or less than 1.3 V/Cell (Cd-Ni batteries) shall release an alarm!

FREQUENCY CONTROL (ISOLATED GENERATOR SET OPERATION)


FREQUENCY CONTROL ENABLED (FOR ISOLATED OPERATION): NO [⌧] YES
SET VALUE OF FREQUENCY CONTROL FOR fmin: [49.8 Hz] Hz
SET VALUE OF FREQUENCY CONTROL FOR fmax: [49.8 Hz] Hz
ADJUSTING PULSE LENGTH FOR SPEED GOVERNOR: [1.0 sec] sec
INTERVAL BETWEEN PULSES: [3.0 sec] sec

INTEGRATED SYNCHRONIZER (OPTIONALLY)


AUTOMATIC SYNCHRONIZER CONFIGURED: YES [⌧] NO
SET VALUE OF DIFFERENCE FREQUENCY: [0.3 Hz] Hz
SET VALUE OF VOLTAGE DIFFERENCE: [8 %] %
CIRCUIT BREAKER’S CLOSING TIME: [100 ms] ms
ADJUSTING PULSE LENGTH FOR SPEED GOVERNOR1): [1.0 sec] sec
1
INTERVAL BETWEEN PULSES ): [3.0 sec] sec
SIGNAL DELAY „SYNCHRONIZATION FAILURE“: [180 sec] sec
ON „SYNCHRONIZATION FAILURE“, LOAD TRANSFER WITH INTERRUPTION: YES [⌧] NO
1
) Identical values as set for FREQUENCY CONTROL overleaf.

ACTIVE POWER CONTROL (OPTIONALLY)


INTEGRATED POWER CONTROL CONFIGURED: YES [⌧] NO
SLIDING POWER VALUE CONTROL (PEAK-LOAD CONDITION) ENABLED 2): NO [⌧] YES
MEASURING RANGE 4 ... 20 mA CORRESPONDS WITH GENERATOR POWER: kW
GENERATOR RATED OUTPUT POWER: kW
SET VALUE FOR CONSTANT POWER CONTROL: kW
POWER CONTROL HYSTERESIS: kW
ADJUSTING PULSE LENGTH FOR SPEED GOVERNOR: [1.0 sec] sec
INTERVAL BETWEEN PULSES (ON LOAD INCREASE): [20 sec] sec
INTERVAL BETWEEN PULSES (NORMAL OPERATION): [3 sec] sec
MONITORING DELAY FOR GENERATOR UNLOADING: [180 sec] sec
SET VALUE FOR REVERSE POWER: kW
SIGNAL DELAY „REVERSE POWER“: [10 sec] sec
2
) When sliding power value control is not enabled, the constant power control is selected automatically.
TA71SXXE.01 - 23 - 07 / 96

TABLE OF RELAY FUNCTIONS


-K 1 -K 4

-K 5 -K 8

-K 9 -K 10

-K 11 -K 12

-K 13 -K 14

-K 15 -K 16

-K 17 -K 18

-K 19 -K 20

-K 21 -K 22

-K 23 -K 24

-K 25 -K 26

LIST OF RELAY FUNCTIONS


The relays are suitable to be configured for the shown in square brackets. The relays marked with
functions listed below. Relays, which are config- an asterisk are assembled on relay unit RZ 071-E.
ured as a standard design for certain functions, are

∗ Generator set running [-K 4] ∗ Fault indication # 13 (NC) ∗ Collective fault signal of all
∗ Starter speed ∗ Fault indication # 14 NC shut-down alarm circuits
∗ Automatic device locked ∗ Fault indication # 14 (NC) ∗ Collective fault signal of all
∗ Battery voltage NC monitor- ∗ Overcrank only warning alarm circuits
ing ∗ Electromagnetic gas valve ∗ Collective fault signal of all
∗ Operate solenoid [-K 12] ∗ Generator out of synchro- only warning NC alarm cir-
∗ Speeding up [-K 13] * nism cuits
∗ Speeding down [-K 14] * ∗ „Close“ pulse for generator ∗ Mains voltage correct
∗ Load decrease circuit breaker [-K 8] ∗ Signal to synchronize to
∗ Fault indication # 1 ∗ Generator voltage correct mains
∗ Fault indication # 2 ∗ Alarm horn [-K 10] ∗ Push-button signal „Alarms
∗ Fault indication # 3 ∗ Electronic governor „On“ off“
∗ Fault indication # 4 signal ∗ Selector signal „Off“
∗ Fault indication # 5 ∗ Signal lamps testing ∗ Selector signal „Hand“
∗ Fault indication # 6 ∗ Speed correct ∗ Selector signal „Automatic“
∗ Fault indication # 7 ∗ Controller „On“ signal ∗ Selector signal „Trial“
∗ Fault indication # 8 ∗ Pre-start conditions „On“ ∗ Selector blocked
∗ Fault indication # 9 ∗ Shut-down solenoid [-K 1] ∗ Firing speed
∗ Fault indication # 10 ∗ Collective fault signal of all ∗ Ignition „On“
∗ Fault indication # 11 alarm indications [-K 9] ∗ No function
∗ Fault indication # 11 (NC) ∗ Collective fault signal of all ∗ Special function
∗ Fault indication # 12 NC alarm circuits
∗ Fault indication # 12 (NC) ∗ Collective fault signal of all
∗ Fault indication # 13 shut-down alarm circuits

RELAYS WITH INVARIABLE FUNCTIONS


The following relays are set on certain functions -K 3 „Generator set available“
and not suitable to be configured for others: -K 8 Continuous signal „Mains c.b. off“
-K 7 Continuous signal „generator c.b. on“
-K 2 Starter relay -K 27 Synchronized „Close“ pulse
TA71SXXE.01 - 24 - 07 / 96

TECHNICAL DATA

DESIGN OF KEA 071-SPL ∗ Nominal voltage 3 x 400 V AC: Setting range


240...280 V
∗ Flush mounting unit ∗ On wrong phase sequence: Indication „U<“
∗ Dimensions (Height/width/depth): 170 / 260 / 80 mm ∗ Generator frequency 50 or 60 Hz: Setting range
∗ Weight: Approx. 2.2 kg 40...70 Hz (continually, <0.1 Hz)
∗ Mounting position: Any ∗ 0 / 4...20 mA for actual generator output
∗ Protection degree: IP 44 (built-in) ∗ 4...20 mA for set value of generator output (from
∗ Ambient temperature (Storage): -20°...+80° C main control station), or optionally:
∗ Ambient temperature (Operating): 0°...+55° C ∗ Battery voltage monitor
∗ Rules / Standards: DIN VDE 0160
INPUTS, OUTPUTS, INTERFACE
POWER SUPPLY
∗ 14 connection terminals, optionally for NC or NO
∗ Via relay unit RZ 071-D: 12 V or 24 V DC / 15 % signal circuits
∗ Operating range: 9 V...35 V DC ∗ 4 fault signal indications of mains voltage integrated
(2 voltage / 2 frequency alarms)
MEASURING AND ANALOG INPUTS ∗ 4 fault signal indications of generator voltage inte-
grated (2 voltage / 2 frequency alarms)
∗ Mains and generator voltage monitor, alterable in ∗ RZ 071-D, containing 12 output relays, 8 of which
steps of 1 V may be configured by user
∗ Nominal voltage 3 x 100 V AC: Setting range ∗ RZ 071-E, containing 15 relays, 14 of which may be
60...120 V configured by user
∗ Nominal voltage 3 x 230/400 V AC: Setting range ∗ Optical fiber interface, for coupling to central control
138...276 V system or to a PC / laptop for configuration works
(via extra hardware / software)

ORDERING NUMBER SYSTEM

Ordering Number for KEA: 2A71S . .

Mains / Generator Voltage: Extension:

Special Voltage or Frequency 0 0 with integr. synchronizer and power control


3 x 100 V 1 1 with integr. power control, without synchron.
3 x 100 V 3 x 230/400 V 2 2 with integr. synchron., without power control
3 x 400 V 3 3 without extensions

3 x 100 V 4 Order Numbers for Relay Units and Cables:


3 x 230/100 V 3 x 230/400 V 5 RZ 071-D: 2R71D00
3 x 400 V 6 RZ 071-E 2R71E00

3 x 100 V 7 Cable KEA → RZ 071-D, length: 1.0 m 1K71100


3 x 400 V 3 x 230/400 V 8 Cable KEA → RZ 071-D, length: 1.5 m 1K71150
3 x 400 V 9 Cable KEA → RZ 071-D, length: 2.5 m 1K71250

Example: Automatic unit KEA for mains stand-by and peak-load operation, suitable for mains and
generator voltage 3 x 230/400 V, fitted with integrated automatic synchronizer and active
power control:

Order Number: 2A71S50


TA71SXXE.01 - 25 - 07 / 96

OUTLINE DRAWINGS

RZ 071-D

Cut-out for door of panel RZ 071-E

CONNECTION DIAGRAM