Terberg Control Systems

Start stop control

Start stop control.

This document describes the configuration and setup of the control and engine systems to start
the engine.
Following issues must be verified:
- Earth connections
- E-stop circuitry
- Engine must be ready to start
- all rated values should be filled in
- sensing lines are defined and connected
- single engine configuration without master

1. Connections from TEC to GECM unit.

Required control signals from TEC to GECM

- Remote start
- Idle rated
- Speed reference
Optional control signals from TEC to GECM
- Alternative dynamics
- Reset
Required control signals from GECM to TEC
- ECM trip
- Engine crank terminate

Optional control signals from GECM to TEC

- ECM alarm
- Emergency Shutdown

Remote start (potential free contact from TEC to GECM)

A potential free contact fed from TEC. If contact is closed and GECM is healthy start sequence
from GECM will be initiated. GECM will energize the starter motor and will start the engine.

Idle rated (potential free contact from TEC to GECM)

TEC will switch to rated 1,5 seconds after that crank terminate is reached.

Engine Speed reference (4..20mA signal from TEC to GECM)

In order to control the speed on a G35xxC type engine, speed control signal to GECM needs to
be connected. The GECM will react on the level, received from its analogue input ‘SPEED
REFERENCE’. For this to achieve, a 4-20 mA signal is applied from the TEC and need to connect
it to the GECM analogue input pin 36 and 37 of P1 connector.

GECM reset (optional potential free contact from TEC to GECM)

If applied any reset given from any (remote) user interface, will give a reset pulse to the GECM if the
engine is not running (In order to reset the ECM the power to the ECM needs to be cycled, that is
why the reset will not be given if the engine is still running)

Version 1.0 r0 Page 1/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

ALTERNATIVE DYNAMICS (optional potential free contact from TEC to GECM )

One can decide to use a different set of PID settings for the speed control in the GECM. The TEC
can be setup to control this status by output K7 (see chapter 3).

ECM Trip (digital output from ECM to TEC)

Contact will be closed if GECM did detect an engine failure. If this contact is received the engine
will be stopped. On receiving this message an alarm is annunciated and the gerenerator circuit
breaker will be opened.

Engine crank terminate (digital output from ECM to TEC)

As soon as the engine start-up cycle is finished the output will be energized. The output will only
de-energize after that the engine is really stopped.

ECM alarm (optional digital output from ECM to TEC)

This output will change state if ECM does detect a warning. Engine will keep on running. TEC will
annunciate the message without any further action.

ECM emergency stop monitor (optional digital output from ECM to TEC)
Status from local E-stop button at engine control is displayed. After pressing, also the ECM Trip
will be activated, but if this signal is connected from TEC it is distinguished that E stop is
pressed

Version 1.0 r0 Page 2/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

Picture TEC-GECM

ACTUAL KW REFERENCE:
To provide the actual kW signal that the G35xxC engine requires for engine control, analogue
output AO0.0 is pre-assigned. This output has a galvanic isolation and matches the GECM kW
input circuitry. This is the reason why the Speed Control Signal is moved to AO0.3 and switched
in mA mode.
I/O configuration
Name TEC GECM
I/O TAG Terminal Terminal
Speed reference AO 3 120 Analogue outputs 2
Idle / rated DO 4 3 Relay outputs 4 J1 j
Remote start DO 5 4 Relay outputs 5 J1 Z
Reset DO 6 163 Relay outputs 6 J1 A
Alternative dynamics DO 7 1 Relay outputs 7 J1 L
Engine crank terminate DI0.1 12 Digital inputs 1 J1 R
ECM Alarm DI0.3 234 Digital inputs 3 J1 U
ECM Trip DI0.5 233 Digital inputs 13 J1 M
Emergency Shutdown Monitor DI0.7 114 Digital inputs 7 J1 t

Version 1.0 r0 Page 3/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

2. Configuration of systems.

CONFIGURATION GECM 1800 PRM 1500 RPM 1200 RPM 1000 RPM
MAX HIGH IDLE SPEED GECM 1890 1575 1260 1050
MIN HIGH IDLE SPEED GECM 1770 1475 1180 983
DROOP GECM (ISOCHRONIC) 0 0 0 0
SPEED REFERENCE TYPE mA mA mA mA

COFIGURATION TEC
MAX HIGH IDLE SPEED TEC 1890 1575 1260 1050
MIN HIGH IDLE SPEED TEC 1770 1475 1180 983
DROOP TEC 3.0 3.0 3.0 3.0

RATED FREQUENCY depending of site requirements (50.00 or 60.00 Hz).

Path = TREE – COMMON – SYSTEM SETUP

System Setup

Settings within this screen can be changed with password level 5. It allows dealers to setup the
system according to systems requirements.

Following screens indicates only the i/o that are described in this chapter

Version 1.0 r0 Page 4/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

Input configuration related to start/stop the engine

Version 1.0 r0 Page 5/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

Output configuration related to start/stop the engine

Analogue output configuration:

The GECM requires a 4-20 mA input signal. To achieve this, the analogue output boundary of
AO0.3 needs to be MIN = 20 % and MAX = 100%. The output type should be CUSTOMIZED.
To have the correct control, AO0.3 needs to be linked with couple number 122 (signal to engine
speedcontrol).

Path = TREE – IO – ANALOGUE – EXTENDED SETTINGS ANALOGUE OUTPUTS

Version 1.0 r0 Page 6/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

Extended Analogue Output

Version 1.0 r0 Page 7/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

3. Functional test and operation.

To achieve best performance of the system, it is required that the engine and GECM control
are running stable and do have optimum performance on frequency or load changes.
To test, one can use ET (Electronic Technician of CATERPILLAR) to do a ‘BUMP TEST’.
Remember to put the Terberg PID control in MANUAL position!

Response of engine might look like:

Frequency response

Version 1.0 r0 Page 8/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

If engine response is instable, adjustment of GECM is required.

Please check which set of settings is used. Depending on what is selected at the process
variables regarding ALTERNATIVE DYNAMICS, the second AUX set might be used.

Next step is to test PID control of the TEC. This can be performed by selecting the speed
control in MANUAL mode and drive the frequency to 51.00 Hz with the RAISE button. Remove
the MANUAL mode and watch the performance on frequency, optional with graph.
Repeat the same step but than to 49.00 Hz with the LOWER button.

For more information on adjusting PID control or how the PID control works, please read “PID
CONTROL” documentation.

4. Advanced Setup.

If more adjustment is required, one can go to the advanced setup part of the system.
Related to speed control, process variables page 4 is required.

Version 1.0 r0 Page 9/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary
 Terberg Control Systems
Start stop control

The extra possibility is the value of the droop setting. Default is 3%. The boundary of Max and
Min High Idle speed allows a droop setting up to 5%.

5. Trouble Shooting

A. Engine has closed synchronizing breaker and is loaded. It does not reach required load set
point in Parallel mode or frequency in island is dropped and not restored.

- Check droop setting in GECM speed control setup. This should be 0.

- Check mA selection on AOUT card and GECM with right terminal connection.

B. Engine is hunting.

- Check mA selection on AOUT card and GECM with right terminal connection.
- Check Max High Idle and Min High Idle Speed settings in GECM.
- Check Max High Idle and Min High Idle Speed settings in TEC system.

C. Manual control is hardly possible.

- Check the MANUAL ADJUST setting on Frequency Control PID.

This is the amount of change, related to time, the output of PID should change.
- Check A and B.

D. When pressed on RAISE button, frequency is dropping in speed and visa versa.

- Check digital input configuration of push buttons if problem exists only on hardware
push buttons.
- Check MIN and MAX value’s in Analogue Output configuration. Default MIN is lower
than MAX value.

E. Engine drops in speed after ‘STABILIZATION’ step.

- Check ‘DIRECTION’ setting in PID control.

- Check MIN and MAX value’s in Analogue Output configuration. Default MIN is lower
than MAX value.

Version 1.0 r0 Page 10/10 Date: 12-6-2008

E-eng 9A0 start-stop_configuration.doc

Preliminary