CGC-MF Split Shaft Steam Turbine - DesignInstallation - Rev H

Si-TEC Xtend series 2
CGC (Co-Generation Control)

for Multi Function (Condensing / Backpressure) Steam Turbines
Design and Installation Manual
Copyright 2009 by Dawson Technology Pty Limited. All rights reserved. This document may not be reproduced or distributed to
a third party without prior approval.
Manual No. 549-022 rev H

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Dawson Technology Pty Limited

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AUSTRALIA
Tel: (07) 38684777 {International: (61)-7-3868 4777}
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Oct-10/rev H
WARNING
Please read this entire manual and all other publications pertaining to the work to be performed
before installing, operating or servicing this equipment.
Practise all plant and safety instructions and precautions. Failure to follow instructions may result in
personal injury and/or damage to property.
WARNING
The engine, turbine or other type of prime mover must be equipped with an overspeed
(overtemperature, or overpressure, where applicable) shutdown device(s) that operates totally
independently of the prime mover control device(s) to protect against runaway or damage to the
prime mover and to protect against possible personal injury or loss of life, should the mechanical
hydraulic governor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s),
the linkage(s), or the controlled device(s) fail.
In the case of generator sets, an effective monitoring system must be available to prevent damages
by overcurrent, voltage differences or reverse power.
PLEASE NOTE
This manual has attempted to provide instructions on the techniques of electronic governing and the
use of accessories, using examples and data that are believed to be accurate.
However, the examples, data and other information are intended solely as a training aid and should
not be used in any particular application without independent testing and verification by the party
performing the application.
Independent testing and verification are critical in any application, particularly where malfunction of
the equipment may result in personal injury and/or property damage.
For these reasons Dawson Technology provides no warranty of any kind, either expressed or
implied, with respect to the contents of this manual, that the examples and data used are consistent
with industry standard and that they meet the requirements of any particular application.
Dawson Technology disclaims any implied warranties for the manual’s quality, performance,
merchantability or fitness for any particular purpose. Dawson Technology also disclaims all liability
for direct, indirect, incidental or consequential damages that result from any use of the examples,
data or other information in this manual.
IMPORTANT
Correct set points must be entered into the Si-TEC Xtend module for each specific application
prior to starting the turbine.
Particular care should be taken with regard to cable shielding and power supply connections to
ensure the equipment meets all requirements specified by Dawson Technology concerning EMI.
CONTENTS
Subject Heading Page
1 Overview Si-TEC Xtend CGC……………………………………………………………….. 2
2 Features Si-TEC Xtend CGC……………………………………………………………….. 3
3 Notation markings…………………………………………………………………………….. 6
4 Input / Output Description Introduction…………………………………………………… 7

4.1 Introduction.……………………………………………………………………………. 7
4.2 Terminology……………………………………………………………………………. 7
5 Control Notes…………………………………………………………………………………… 8
6 Logic Inputs…………………………………………………………………………………….. 9
6.1 Fixed Logic Inputs…………………………………………………………………….. 9
6.2 User Select Logic Inputs……………………………………………………………… 10
7 Relay Outputs…………………………………………………………………………………. 15
7.1 Fixed Relay Outputs…………………………………………………………………. 15
7.2 User Select Relay Outputs………………………………………………………….. 15
8 Analog Inputs…………………………………………………………………………………. 20
9 Analog Outputs……………………………………………………………………………….. 22
10 Analog AVR Bias Output…………………………………………………………………... 24
11 Turbine Governor Connections…………………………………………………………… 25
12 Voltage and Current Sensing…………………………………………………………….. 26

12.1 Voltage Sensing Inputs……………………………………………………………. 26
12.2 Current Sensing Inputs……………………………………………………………. 26
13 Power Supply……………………………………………………………………………….. 27
14 RS485 and RS232 Communications……………………………………………………. 28

14.1 RS485 Si-TEC LAN – Terminations……………………………………………… 28
14.2 RS485 User LAN – Terminations…………………………………………………. 28
14.3 RS232 Communications / Diagnostics Port………………………………………. 28
14.4 CAN BUS – Terminations…………………………………………………………… 28
14.5 Interface with Dymec Fibre Optic Links (Half Duplex)……………………………. 28
15 Installation Notes…………………………………………………………………………… 29
16 Additional System Options …………………………………………………………… 30
17 Si-TEC Xtend CGC and GSM Vector Disturbance Relay Description……………… 31
18 Si-TEC Xtend Communications Addresses accessed from RS232 Communications

/ Diagnostics Port and User RS485 Port……………………………………………………. 32
18.1 Generator Module Data Reference (2000 range – read only)…………………… 34
18.2 Generator Module Address Offset Data (6000 – 8300 range – read only)……. 36
18.3 Generator State Table (2000 range address offset 1)……………………………… 37
18.4 Generator Status and Alarm Tables (logic items)………………………………… 38
18.5 Generator Logic Input 1&2 Tables…………………………………………………. 38
18.6 Generator Multiplier for kWatt, kVAr & Volt Table (address offset 0)………….. 39
18.7 Process Limit Table…………………………………………………………………. 39
18.8 Communications Analysis Addressing……………….……………………………. 40
Appendix – Si-TEC Xtend Control Technical Details and Illustrations………………… 43
1
1. OVERVIEW OF THE Si-TEC XTEND CGC
Co-Generation Control (CGC)
The Si-TEC Xtend Co-Generation Control (CGC) is a 32–Bit microprocessor-based turbine-generator

control system that incorporates all its functions within a single module. These include digital speed
governing, automatic synchronising, kWatt and kVAr/PF load control, along with extensive secondary
functions. The CGC is suitable for single or multiple generators used in “Islanded Operation”, as
well as for applications that require the generator to operate in parallel with the “Supply Authority
Mains” (Grid).
Using the CGC, the generators may synchronise and parallel under various operating conditions.
These include:
1. Isolated prime power stations.

2. Prime power stations that parallel and are “base loaded” (constant supply) to the mains, allowing
for the import of power from the mains during peak demand periods.
3. Prime power stations that supply power for internal load requirements, and export excess power
to the mains.
4. Prime power stations that only export power to the mains.
5. Standby power stations, where parallelling to the mains is not required.
6. Standby power stations where automatic soft (bump less) load transfer back to the mains (Grid) is
required, with no exporting of power to the mains.
7. Standby power stations used for “peak shaving” (peak lopping) applications where the generators
parallel with the mains during peak demand periods, setting a maximum limit for the imported
mains power.
The import / export control involving multiple generators may be further enhanced with the use of a
Si-TEC Xtend Generator System Master (GSM) control system.
The detection of the loss of supply authority grid power is available when operating in parallel to the
grid. This feature is described as "Vector Disturbance” (refer to page 30).
NOTE: This manual version (549-022 rev H) is applicable up to the Si-TEC Xtend CGC control
software program version BX_1.01n, that is current for Oct 2010.
2
2. FEATURES OF THE Si-TEC XTEND CGC
Precise Turbine Governing with a steady state speed variation within +/- 0.1% of operating (rated)
speed. The typical steady state speed variation for most steam turbines is +/- 0.05% of rated speed.
Capability of driving a variety of all-electric and electro-hydraulic actuators via the “Actuator
Output” for optimum fuel (speed) control. For the All-Electric actuators (i.e. StG range), “Actuator
Position Feedback” is provided. Interface with OEM or other actuators (eg. electro-hydraulic,
pneumatic, etc.) are available including 0 – 20 mA, 0 – 200 mA, 0 – 5 Vdc, +/- 10 Vdc, etc.
Automatic control valve ramping and positioning during initial turbine start up, incorporating a
“Guaranteed” start function via StG all-electric actuator.
Multiple speed PIDs (6 Speed PIDs available) for controlling a wide range of turbines operating
under a variety of different applications and conditions.
Automatic Starting Sequence can be initiated using the “Start Seq” logic input, providing actuator
ramping and limiting, speed ramp up, warm-up sequence (including “Temperature Hold” function
during start sequence), synchronising, load sharing for kWatt and kVAr control, with a shutdown
sequence including a cool down period. The timed warm-up sequence may be overridden at any time
during the start sequence (except “Critical Speed Bands”) via the “Sequence Hold” logic input
function. An immediate shutdown of the turbine-generator may be carried out by disabling the
“Enable Run” logic input, which should be interlocked with “emergency shutdown” devices.
The CGC governor requires a speed sensor that may use either a magnetic pickup (MPU) or
proximity switch (Prox) for actual speed measurement. A second speed sensor may also be utilised
for redundancy requirements. Typically, an MPU is used for most steam turbine applications.
Automatic Synchronising Control which carries out frequency, phase and voltage matching
(monitoring and adjustment) of 3-phase generator and bus potential transformers (PTs). The time
for synchronising is less than 10 seconds (typically within 5 seconds for a 0.1 Hz slip, 1% voltage and
5° phase angle window) for most applications. The synchronising close signal is enabled by a
completely independent synchronising check hardware, providing a dual-function verifying system.
Phase rotational check (for both generator and bus voltages) may also be performed during
synchronising. Upon synchronisation, an automatic generator circuit breaker (CB) closure signal is
issued via the “Close CB” relay output.
Automatic kWatt Control with accuracy within 0.5% (full-scale). kWatt control commences upon
confirmation of generator CB closure, through a “Gen CB” logic input signal. True RMS load is
sensed via generator potential transformers (PTs) and current transformers (CTs), allowing the
generators to kWatt load share in Island (Isochronous) operation (via Si-TEC LAN). This includes
kWatt Load Ramping, which provides adjustable soft loading and unloading ramp rates. The
generators may also function in a number of load control modes using CGC and GSM modules. For
instance, the generators when paralleled to Grid may supply load based on an import/export kWatt
reference from the Grid, or operate at a preset or adjustable base load reference. The kWatt limits
are active during Grid parallel mode, between the “Min kWatts” and “Rated kWatts”.
Capability of directly interfacing with wide range of AVRs (Automatic Voltage Regulators) through the
“AVR Bias” analog output OR relay outputs (analog bias is preferred for optimum control). The AVR
Bias function allows Island (Isochronous) kVAr/PF load sharing (via RS485 Si-TEC LAN) between
generators. In addition, Automatic Power Factor Control of the generator is achieved at a preset
power factor reference when paralleled to the mains (grid). The kVAr limits are active during Grid
parallel mode, between the “Leading kVArs” and “Rated Power Factor” of the generator.
kWatt Limiting of individual turbine-generators, using 4-20mA inputs.
Sensing the loss of the supply authority mains while running in parallel within a 40 mSec period.
This function operates via a relay output to separate the station from the mains (grid), thus retaining
full operation of the plant generators (i.e. generators will not trip on over-current or under frequency).
This detection is known as "Vector Disturbance" and applies to Grid parallel applications only.
3
Sixteen (16) logic inputs, of which 12 inputs may be user defined for a wide range of applications.
These include “Hot Start”, “Fast Rate”, “Sequence Hold”, “Base Load”, “Group Select”, “Overspeed
Test”, manual “Speed Raise/Lower”, manual “Voltage Raise/Lower”, “Process Enable”, “Process
Raise/Lower”, etc. The fixed logic inputs are “Enable Run”, “Start Sequence”, “Generator CB Aux”
and “Mains CB Aux”.
Nine (9) relay outputs (including the dedicated “Close CB” relay output) with LED indication status,
of which 8 outputs may be user selected for the operation of control or alarm outputs.
The relay output control functions include:

Fuel solenoid Low Inlet Pressure
At Running Speed High Inlet Pressure
Trip Generator CB Low Exhaust Pressure
Raise Voltage High Exhaust Pressure
Lower Voltage
kWatt level switch (1) and (2)
Generator CB closure (fixed output)
Speed Switches (1) and (2)
Lubricate Output **
kWatt Hour Pulse
kVAr Hour Pulse
Synchronising
Hz and Volts OK
The relay output alarm functions include:

Reverse Power
High kWatt
Phase Unbalance
High kVAr
Reverse kVAr (under excitation)
Under Frequency
Over Frequency
Under Voltage
Over Voltage
Combined alarms (1) and (2)
Latched alarms (1) and (2)
DC Supply Volts Low
Enable Dead Bus Timeout
Gen CB Close Failure
Gen CB Open Failure
Sync - Failure
Speed Sensor Failure
Vector Disturbance (loss of utility supply whilst connected to mains)
Each or the alarms can be selected to be “Disabled”, “Enabled”, or to “Trip” the generator CB. Alarms
may be reset by the keypad, logic input or by communications. In addition, combined alarm output
relay(s) may be selected for the indication of alarms.
Four (4) analog inputs (3 X 4-20 mA and 1 X RTD) that are user selected for customer requirement
(e.g. kWatt / kVAr Referencing, kWatt Limiting, etc.) either hardwired or via Modbus communications.
Three (3) user selected analog outputs (4-20mA) for direct driving kWatt, kVAr, PF metering,
turbine speed and actuator output. These outputs may be configured to suit customer's requirements.
RS232 communication / diagnostics port for tuning and troubleshooting purposes. The RS232 port
is utilised for Dawson Technology PC support software interface, providing turbine and generator
control tuning (pcTune) and storage of set point data to a PC (pcConfigure). The port can also be
interfaced with a dial-up modem for remote tuning and/or monitoring (via the pcTune).
4
A RS485 “Si-TEC LAN” communication port for Si-TEC Xtend device inter-communication. Up to
24 Si-TEC Xtend modules may be networked on the “Si-TEC LAN”, comprising of a combination of
generator and master modules. Hence, multiple GSM Master modules may be included in a single
system network if required (eg. applications involving a generator bus tied to multiple Mains feeders).
A RS485 “User (Customer) LAN” communication port, which allows for read/write functions from/to
the extensive address range of the Si-TEC Xtend modules. Both Modbus RTU and ASCII protocols
are supported on the “User (Customer) LAN” port.
A CAN BUS communication port for interface with the Opal Generator Annunciator, Secondary
Actuators, RIO (Expansion I/O) module or Temperature Scanner (Thermocouple or RTD). The
“Opal” has dedicated turbine monitoring and alarm functions. The RIO module allows for additional
Logic Inputs, Relay Outputs and Analog Inputs to be incorporated into the control system, if the
existing Si-TEC Xtend I/Os are limited for the specific application.
The set up data is stored in a non-volatile memory (EEPROM) of the Si-TEC Xtend microprocessor.
On-board programming is possible through the face mounted industrial designed keypad. A 20-
character 4 line (80 character) display shows set points and other menu items.
The menu driven readout displays full system information including:

1. Individual phase and totals of current, voltage, kWatt, kVAr, and power factor.
2. Peak Hold values for RPM, Phase kWatts, Phase kVAr, and Phase Currents.
3. Accumulated Data values including kWatt hours, kVAr hours, Run Hours and No. of Starts.
4. “First Up” alarm display.
5. All control input and output parameters.
6. Logic and Analog inputs and outputs.
7. Speed and Actuator monitoring.
8. Control preset values and adjustment for tuning to suit the characteristics of an extensive range of
prime movers and applications.
9.Comprehensive diagnostics for checking the governing system while the turbine is stationary,
excitation testing, module I/O test facilities, and communications testing.
The CGC modules can be controlled by a Generator System Master – Grid (GSM-G) control
module, providing extensive kWatt and kVAr referencing for a maximum of four groups of generators.
This referencing may be used for Import/Export control, total station requirements, or percentage of
generators’ ratings. The GSM master module further provides for a common station frequency and
voltage reference when operating in the islanded mode. The station monitoring of the system and all
generators is available via the “User RS485” communications port of the GSM Master (Grid) and
CGC control modules.
For islanded operating power stations, a Generator System Master – Islanded (GSM-I) control
module can provide true time error correction typically better than 1 minute per year, as well as a
common station voltage and frequency set point for the “Island” load sharing generators. The station
monitoring of the system and all generators is available via the “User RS485” communications port of
the GSM Master (Island) and CGC control modules.
The module has plug in connectors (with exception of the C.T. terminations), enabling the
switchboard manufacturer to be provided with a "blank" module for initial termination. Exchanging the
complete module (control system) can be conducted within a few minutes, making on-site
replacement quick and efficient.
After the system has been set up and commissioning is complete (refer to the “Set Up and
Commissioning Manual”), the set points may be extracted via the RS232 port and stored in a PC
using our Si-TEC pcConfigure software. If the necessity arises to replace a module all the preset
values can quickly down loaded to the control module.
5
3. NOTATION MARKINGS
Items marked " ** " are not implemented at this present stage.
System Designers should made special note of items marked "##"
6
4. INPUT / OUTPUT DESCRIPTION
4.1 Introduction
The Si-TEC Xtend CGC control module is a 32-bit pre-programmed microprocessor control operating
with a combination of designated inputs and outputs for steam turbine-generator control. In addition to
the "standard" control inputs and outputs for start/stop sequencing, speed governing, synchronising,
load control, etc., a number of inputs and outputs are provided for user application selection. The Si-
TEC Xtend CGC control module is supplied with default settings for several input and output
functions. These settings may differ for each application requirement and therefore it may be
necessary to verify all preset values prior to the initial starting of the turbine-generator. The first part
of section 6 (page 8) describes the fixed inputs and outputs. The subsequent part of section 6 (page
9) outlines the user select input and output options. This provides information for the relevant
application documentation and drawings, together with details of the input and output features and
capabilities of the Si-TEC Xtend control module.
4.2 Terminology
The following is a description of terms used within this document:
Analog Input: RTD, 0-5V, or 4-20mA input signals.
Analog Output: 4-20mA output for driving external metering etc.
Logic Input: a switched input voltage (nominally 24Vdc).
Relay Output: voltage free contacts for providing output control.
High Input: when 24Vdc is applied to a logic input.
Low Input: when the logic input has 0Vdc applied.
Preset Value: default set point value of an internal control function, which is adjustable via
the menu system for final application settings.
Generator CB: the respective generator circuit breaker.
Mains CB: the circuit breaker(s) connecting the main bus to the incoming supply, supply
grid or utility.
Vector Disturbance: the rate of change of phase angle for detecting loss of the supply authority
(mains) grid.
SP: Set Point or Reference Value
PV: Process Variable or Measured Value
7
5. CONTROL NOTES
## THIS IS A CONTROL DEVICE AND IS NOT TO BE USED FOR TURBINE SPEED

PROTECTION. SEPARATE INDEPENDENT SAFETY SHUTDOWN DEVICES MUST BE
USED FOR OVERSPEED PROTECTION.
## The internal Si-TEC Xtend alarm functions may be selected to operate the module's CB trip
output and/or to switch an output relay. Internal tripping of the generator CB should be
interfaced to latching circuit(s) to inhibit generator control under such alarm conditions. This
provides flexibility to suit the required control operation. The alarm relay outputs are only
operative under an “Alarm” condition, and do not latch within the module. All latching for
alarm indication and/or control interfacing should be conducted external to the module.
## Alternatively, the alarms may be allocated to a “Combined” latched alarm function. This latch
may be reset by pressing the “Reset” key on the keypad, or by using the “Remote Reset”
logic input. For this purpose a combined latched alarm may include numerous alarm
functions, with the allocated “latched relay” wired in series with the Si-TEC Xtend logic input 2
(Start Seq.) for a controlled shutdown or wired in series with logic input 1 (Enable Run) for an
immediate shutdown. Operation of the reset function will unlatch this relay.
## Upon the operation of various alarms it is desirable to "advise" the Si-TEC Xtend module of a
change to the required control state, by de-energising the relative logic input(s). For example
if reverse power is sensed, internally or externally trip the CB, de-energise and latch out the
Start Seq. input (input 2), which then places the module into the cool down operation mode.
Without de-energising input 2 the module is still instructed to operate normally. In this
situation the control realises that the Gen CB input (logic input 3) is de-energised, and with
input 2 energised the mode of operation would be to re-synchronise the generator with the
bus. By de-energising input 2, the mode changes to the normal "off line" sequence of a “cool
down” period followed by a controlled shutdown operation. Likewise should a turbine fault be
detected (eg. Low Lube Oil Pressure or High Inlet Temperature), it would be advisable to de-
energise and latch out the Enable Run input (input 1) for immediate shutdown. The shutdown
control modes (whether by input 1 or 2) operates the CB trip/open signal as part of the
shutdown procedure.
## Refer to the following sequence operation of logic inputs 1 and 2 (section 4.2, page 64).
## CB close relay contacts momentary close when generator is synchronised signalling for the
Circuit Breaker to close. The relay is de-energised should the generator move out of
synchronisation and/or if the Generator CB auxiliary input (via input 3) signals that the circuit
breaker has closed (after a 1-second delay to prevent "pumping" of the CB). This relay
operates as a maintained output if a CB trip relay is not selected.
## The Generator CB auxiliary input (input 3) and the Mains CB auxiliary input (input 4) should
instantaneously receive their status signal change (or with minimum time delay), after a
change in the actual respective CB status. This is critical in ensuring that the Si-TEC Xtend
CGC operates in the correct control mode.
## It is strongly recommended that all external interposing relays for the CGC modules be
equipped with a protective circuit (eg. Diode 1N4007) across relay coil (if coil is for DC
currents), to eliminate high voltage spikes due to “Back EMF”.
8
6. LOGIC INPUTS
## The logic inputs may be powered from an external 24Vdc supply, provided the supply negative
is linked to the logic input common (input 0). The logic input voltage may range from 9 to 36
Vdc, however 24Vdc is recommended.
Various logic inputs may be configured to suit the user application. Refer to the Menu Functions and
settings for further logic input options and selection. The following list is a description of the fixed logic
input control functions. It should be noted that more than one input control function may be assigned
to a single common logic input. Input functions may be set to:“0” or “always OFF”, “1” or ”always ON”,
or allocated to a switched logic input.
6.1 Fixed Logic Inputs
Enable Run - Input 1 (terminal 1)

## Logic Input 1 is required to be “High” (energised) for the turbine-generator unit to run. De-
energising input 1 will immediately trip the generator circuit breaker, drive the actuator to zero fuel
and de-energise the fuel solenoid output.
The turbine "fault shutdown" or “emergency shutdown” devices should be interlocked with this input
and externally latched off.
Start Sequence - Input 2 (terminal 2)

This logic input initiates the normal starting and stopping of the generator. The normal sequence of
operation is described below.
Upon input 2 going "High" (provided input 1 is "High"):
1 The “Fuel Solenoid” relay output (if configured) is energised to open the turbine Main Steam
Valve. If this function is not used, the Main Steam Valve may be manually opened before
energising the “Start Sequence” input.
2 The governor actuator is positioned at the “Initial Actuator Start Position”. The actuator will begin
to open at the “Increase Actuator Limit Position %/sec” ramp rate until the “Warm Up 1 Max. Act.
Position”. If no speed is achieved after a duration based on the “Start Fail Timeout”, a ‘Start Fail
Alarm’ is issued. The “Start Sequence” would need to be re-issued (toggled Off-On) after the
alarm is reset.
3 Under normal conditions, the turbine speed should pick up during the “Increase Actuator Limit
Position %/sec” and will revert to speed PID control once the turbine speed reaches “Warm Up 1
RPM”.
4 After the “Warm Up Time 1” is completed, the turbine will ramp up to “Warm Up 2 RPM” speed.
5 After the “Warm Up Time 2” is completed, the turbine will ramp up to the “Idle RPM” speed.
6 It should be noted that two (2) Critical Speed Bands are available, if required. The Critical Speed
Bands may be set in the range between “Warm Up 1 RPM” and “Rated Speed RPM”.
7 After the “Idle Delay Time” is completed, the turbine will then ramp to the “Rated Speed RPM”.
8 The turbine then warms up for a further duration based on the “Warm Up Time at Rated RPM”.
9 The “Hot Start”, “Fast Rate” and “Sequence Hold” logic inputs have an impact in the turbine start
sequence, and their specific functions are described in section 3.10 (Logic Inputs).
10 Upon the generator excitation, the control then synchronises the incoming generator to the main
bus (or grid) after matching frequency, phase angle and voltage. Phase rotation is further
checked before permitting the closure of the "Close CB" output terminals 17 & 18 (fixed
designated relay output).
11 kWatts and kVArs are ramped at a preset rate (e.g. 0.5% per sec) until load is shared with the
other sets on the bus, or if the unit load reaches its set point (base load) reference.
Upon input 2 going "Low" (removal of "Start Seq." signal):
1 Generator load ramps down at the preset rate (e.g. 1.0% per sec). kWatts and kVArs must
unload below the preset levels prior to the normal switching off line (opening the CB). Should
unloading not occur within a preset maximum time, the switching off line will occur regardless of
the kWatt/kVAr levels.
2 The generator runs at the “Cool Down Speed RPM” for the preset “cool down” time.
9
3 Following the cool down period the actuator drives to zero (0%) position and the fuel solenoid
output (if used) is de-energised. The turbine-generator is then fully shutdown, and is ready for
another start sequence.
4 Removal of the signal to input 2 resets the controller following any alarm condition (e.g. Reverse
Power).
## Note: Latch out input 2 if the CB is tripped under a fault condition. This will "advise" the Si-TEC
Xtend module of a sequence stop requirement and prevent any re-synchronising mode occurring.
Switch input 1 to “Low” for an immediate shutdown.
Generator CB Closed - Input 3 (terminal 3)

## Input 3 is to be “High” (energised) when the generator circuit breaker is closed. This input is
typically derived from the circuit breaker auxiliary contacts. On receiving a “High” signal the Si-TEC
Xtend controller confirms that it is “Online”, and performs the kWatt and kVAr sharing / control
functions (except as a Isolated Single unit). It is critical to verify the correct input status should the
generator not be taking load. Faulty auxiliary contacts of the generator CB will affect the requirement
to operate under proper load control and load sharing conditions.
Mains CB Closed - Input 4 (terminal 4)

## Input 4 is to be “High” (energised) when the generator is paralleled to the supply authority
mains. With this input being "High" and the Gen CB closed (input 3), the Si-TEC Xtend controller will
operate under the control of “Grid Paralleled” P.I.D. settings. This input is typically energised from
the Mains incoming CB auxiliary. Should there be additional CBs along with the Mains CB (eg. Mains
CB at HV side) it is necessary to series interpose multiple CBs with Mains Aux. contact input.
6.2 User Select Logic Inputs
User select logic input functions may be allocated to the logic input terminals or alternatively set to
“always OFF” by setting to "0" or to “always ON” by setting to "1".
It should be noted that more than one input function may be assigned to a common logic input.
The terminals available for the switching of the user select logic input functions include:
Logic Input Terminals 5 to 16 (total of 12 user select inputs)
The following control functions may be allocated to a switched logic input or be set to always ON or
always OFF. The functions are listed in the order displayed in the control module:
Enable Input Control via Modbus

Remote Fault Reset
Rated Speed
Over Speed Test
Fast Rate
Sequence Hold
Barring complete **
Synchronise Inhibit
Enable Load Share
kWatt Re-Rate
Base Load Mode (1)
Base Load Mode (2)
Gen Group 1 to 4 1st Bit
Gen Group 1 to 4 2nd Bit
Main Bus, Re-Sync to GRID
Enable Min. Import
Sum Import Sensors
Manual Speed Increase
Manual Speed Decrease
Manual Volts Increase
Manual Volts Decrease
10
Auto Input
Hot Start
Permissive Sync. Mode
Dead Bus Enable
Enable Process Control
Process Ref. Analog
Process Increase
Process Decrease
Enable Input Control via Modbus

This function permits the switching of selected input functions via the User (Customer) RS485
communications. The Modbus Digital Input Write address range is from 4040 to 4075.
Remote Fault Reset

Provides for the reset of the Si-TEC Xtend alarm faults from a remote point, besides the on-board
reset key on the keyboard.
Rated Speed
This logic input is required to be "High" for the turbine-generator to run at the preset operating speed.
With this input at “Low”, the set will remain at the preset idle speed.
Over Speed Test Select

When set “High”, this function provides for an over speed test procedure only when turbine is in
“Ramp to Cool Down” or “Cool Down” state (Start Seq input is “low” and Auto input is “high”). The
unit will ramp to the preset “Overspeed Test” reference (menu 160), which should be set slightly
higher than the speed (RPM) where overspeed trip protection will operate. If the overspeed protection
operates correctly, the “Overspeed Test” reference setting will not be achieved. Should the
Overspeed trip test fail, the turbine will be controlled by the “Overspeed Test” reference. De-
energising this input function would then ramp the turbine back to the Cool Down speed level.
Fast Rate
If this input is “High” during starting, the fast rate mode is initiated. This mode bypasses the timed
periods of idle and warm up, and a more rapid idle to operating speed ramp rate will result.
Sequence Hold
Provided the turbine-generator is anywhere between “Warm Up 1” speed and below the “Rated”
(Operating) speed, the CGC “Start Up” sequence will "Halt" at that specific speed when ”Sequence
Hold” is switched “High”. The following conditions concerning the “Sequence Hold” input function
should be noted:
1) Upon switching the “Sequence Hold” to “High” when the turbine is at a warm up level (eg. “Warm
Up 1”, “Warm Up 2” or “Idle”), the respective timer duration “Countdown” will continue till 0.0
minutes regardless of the “Sequence Hold” state. Once the duration timeout is reached, the
“Sequence Hold” function ensures that the turbine remains at this warm up level indefinitely.
Upon “Sequence Hold” being released (i.e. switched “Low”), the turbine speed will immediately
ramp to the next warm up level.
2) While the turbine speed is ramping between warm up levels (eg. from “Warm Up 1” to “Warm Up
2” level), switching the “Sequence Hold” to “High” will halt the sequence at the ramp speed
reference and maintain this speed indefinitely or until it is switched “Low”.
3) If the “Sequence Hold” is switched “High” during a “Critical Speed” band, the turbine speed will
continue ramping at the “Critical Speed Band” ramp rate until the turbine is outside the “Critical
Speed” band. At this point, the “Sequence Hold” function will halt the sequence at the ramp speed
reference and maintain this speed indefinitely or until it is switched “Low”.
4) The “Sequence Hold” function also stops the speed ramping during “Ramp to Cool Down” state.
5) The “Sequence Hold” function when switched “High” after turbine has reached “Rated” speed” will
prevent / stop the “Synchronising function”, and maintain turbine at no load Rated Speed.
6) The “Sequence Hold” function when switched “High” after turbine generator is online (i.e. Gen CB
closed) will “Hold” the load reference setpoint indefinitely until switched “Low”. This will override
other functions (i.e. “Base Load”, “Process Control”, “Grid Droop”, etc.)
7) The "Sequence Hold" function is overridden immediately should input 1 (Enable Run) go “Low”.
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Synchronise Inhibit
Disables the CB close signal when this function is switched high during the generator synchronising
operation.
Enable Load Share Select

Set function to always ON, unless there is a requirement to switch the generator out of load sharing
mode (eg. bus-coupler opened, connecting this generator to other generators). Disables control from
a GSM master module (when paralleled to Grid), reverting to the generators own set points. The
“Enable Load Share” logic function should only be disabled (“Low”) when paralleled to the grid as a
single CGC unit with no GSM Master reference.
kWatt Re-Rate
If this input is “High” the kWatt re-rating preset value of the generator is used for load sharing
calculations. A common use for this feature is to re-rate the output on a pre-alarm over temperature,
enabling time for an additional set be started and switched on line prior to shutdown. The preset value
may also be set higher than the rated kWatt, providing a proportional increase in load when this input
is activated.
Base Load (1 and 2)

This function facilitates the operation at two different base load settings for both kWatt and P.F. When
this function is switched “High” the generator will operate as a base load machine. The kWatt
reference being the preset menu item ”Base Load kW”, or if configured as a 4-20mA kWatt reference.
Base Load 1 and Base Load 2 may be preset, or externally adjusted via Logic and Analog inputs
respectively. The kWatt control priority levels are: (1) Base Load 1 set point, (2) Base Load 2 set
point, (3) Process Control Setpoint (if used), (4) Master (GSM) reference set point, (5) Grid Paralleled
kWatt set point {“1” highest and “5” lowest}.
Gen Group 1 to 4 – (1st Bit and 2nd Bit)

The grouping control is an option of the Si-TEC Xtend modules. This group control provides for the
load sharing of generators into 4 different groups. Suited for applications where bus couplers, feeders
etc. can separate the generators into different groups. The “Group Control” provides for the load
sharing and kVAr sharing of such “split groups” without switching the Si-TEC LAN communications.
The switching of the group input function changes the group for this generator. The two bits switch
the group control in a matrix as follows.
Bit 1 Low, Bit 2 Low = Group 0
Bit 1 High, Bit 2 Low = Group 1
Bit 1 Low, Bit 2 High = Group 2
Bit 1 High, Bit 2 High = Group 3
Main Bus - Re-Sync to Grid

Energise input to re-synchronise to the utility grid (may go low after main CB closed).
Operative only when gen CB (input 3) closed and mains CB (input 4) open.
Used where a single generator and its connected load are required to re-synchronise back to the
utility grid. The close CB relay output of the Si-TEC Xtend module being re-directed from the
generator CB to the mains incoming CB. An external change-over relay is required to switch the CB
closing signals, and Grid voltages to Bus voltage inputs (use a 2-pole, 6-way switch).
Enable Minimum Import Select

This control function provides for a kWatt limiting control on the incoming supply. For a single CGC
controlled generator, a kWatt bi-directional transducer can be installed measuring the incoming
supply from the utility grid. A 4-20mA signal from this transducer provides an input to a Si-TEC Xtend
4-20mA analog input. The kWatt minimum import set point can be set negative or positive to limit the
kWatt export or to provide minimum import. This logic input function needs to be “High” to activate
this function. This input could also be set to ‘always ON’, which maintains the limiting control function.
Manual Speed Increase

Increases the speed when in the manual mode (Auto is “Low”). Refer to the “Auto” input description.
This adjustment will also increase the kWatts (real power) when the generator CB (input 3) is closed.
12
Manual Speed Decrease
Decreases the speed when in the manual mode (Auto is “Low”). This adjustment will also decrease
the kWatts (real power) when the generator CB (input 3) is closed.
Manual Voltage Increase

Increases the alternator voltage bias when in the manual mode (Auto is “Low”). Refer to the “Auto”
input function. This adjustment will also increase the kVArs (reactive power) when the generator CB
(input 3) is closed.
Manual Voltage Decrease

Decreases the alternator voltage bias when in the manual mode (Auto is “Low”). This adjustment will
also decrease the kVArs (reactive power) when the generator CB (input 3) is closed.
“Auto” Input menu 438

This input is to be “High” (energised) for automatic operation and “Low” for manual operation. The
manual/auto refers to the Si-TEC Xtend control mode and does not relate to the external control
system automatic / manual operations. For all normal operations this input should be energised,
allowing the steam turbine-generator to function in the automatic start sequence and load
sharing/control mode. Hence, the preset configuration for the “Auto” input logic function is always
ON. It should be noted that the Si-TEC Xtend manual mode function is intended only as a
“technician’s tool” and not as the normal mode of operation.
“Auto” Input – “Low” (Manual Mode)

When the “Auto” input is “Low” the manual operation is activated, and the preset actuator position
droop or kW droop is introduced. In the manual mode the turbine-generator’s speed/kWatts and
Volts/kVArs will remain at the level prior to switching to manual. The logic inputs for Volts (kVArs)
adjust and for speed (kWatts) adjust are only functional as raise/lower inputs while in manual mode.
If switched to the manual mode while the circuit breaker is open, the speed and voltage of the
generator remain at the levels prior to switching. If switched when the generator circuit breaker is
closed, then the generator kWatt and kVAr remain at the levels prior to switching. The exception
being that when input 1 (Enable Run) goes “Low”, the relay outputs for the generator CB and fuel
solenoid open immediately, resulting in any immediate shutdown of the turbine-generator unit.
Under manual control the generator speed control will operate under “droop” mode. The droop can be
referenced to kWatt loading or Actuator position. Refer to “Manual Control Sub Menu” - “Select Droop
Mode” (menu item 405 in the “Set Up and Commissioning Manual”).
The automatic adjustment of load as described below under "Sequence Hold", does not function in
the manual mode.
Note: In the manual mode the system mode state does not change, except on start up where the
initial hold state is in the synchronising mode (automatic CB closure is inhibited). In addition, the
turbine-generator will not go through the sequence shutdown if it is in manual mode.
“Auto” Input – “High” (Automatic Mode)

When the “Auto” input is “High” the automatic operation is activated. If the turbine-generator is at
operating speed, automatic operation ensures that the generator commences synchronisation with
the load bus and issues a “Close CB” relay output command to parallel the unit with the load bus.
This condition is possible only if the “Start Seq.” input (input 2) is “High”, and “Synchronise Inhibit”
input is “Low” or configured to always OFF.
Upon the generator CB closure (i.e. input 3 is “High”), the active power (kWatt) and the reactive
power (kVAr) are automatically controlled to maintain a balance between all sets on line. The kVAr is
controlled via the motor operated potentiometer or analog AVR bias trimming and kWatt load via the
actuator.
In addition if there is no master module in the system, turbine speed and alternator voltage are
controlled to each operational unit’s preset frequency and voltage. These need to be set at exactly
the same value for all units, in order for isochronous load sharing to function. If a GSM master is
enabled, it sets the bus frequency and voltage references for island generators via the Si-TEC LAN.
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Hot Start Select
If selected (switched “high” or “always ON”), this will set the warm up time values based on the
following menu items:
(1) “Warm Up at Rated RPM Hot”

(2) “Warm Up 1 Time Hot”
(3) “Warm Up 2 Time Hot”
(4) “Idle Delay Time Hot”
(5) “Warm Up Duration at kWatt Setpoint Hot”
Permissive Sync. Mode Select

This function provides a controlled CB closure when in Manual mode (“Auto” input – low). This allows
for manual synchronising (using the Raise / Lower Speed and Voltage inputs) to be carried out, and
permits the generator CB closure via the “CB Close” relay output when the synchronising parameters
are met. Refer to Appendix section for more details.
Dead Bus Enable Select

This function allows the individual control unit to perform a “Dead Bus Closure” for its generator CB,
and is based on the values set in menus 300, 301 and 302. Refer to the Appendix for more details.
Enable Process Control Select

When switched “High”, Process Control is enabled, and when switched “Low”, Process Control is
disabled.
Process Ref. Analog Select

This logic function allows the use of 4-20mA analog input for Process Reference. When switched
“High”, Process Control Ref. via 4-20mA analog input; when switched “Low”, Process Control Ref. is
via Internal Setpoint (M# 915), adjustable via Process Increase / Decrease logic inputs.
Process Increase Select

Increases the process reference when using Process Digital Ref. (“Process Ref. Analog” input is
“Low”).
Process Decrease Select

Decreases the process reference when using Process Digital Ref. (“Process Ref. Analog” input is
“Low”).
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7. RELAY OUTPUTS
Relays 1, 2, 3, and 4 are N.O. contacts and use a common supply (terminal 19).
The terminals for these relays are:
R1 R2 R3 R4
N / Open 20 21 22 23
Common 19
Relay contact ratings: 2A @ 250 VAC or 30VDC;

minimum switching 10mA at 5VDC
Relays 5, 6, 7, and 8 have N.O. & N.C. change over contacts and an isolated common for each relay.
The terminals for these relays are:
R5 R6 R7 R8
N / Open 24 27 30 33
Common 25 28 31 34
N / Closed 26 29 32 35
Relay contact ratings: 5A @ 250 VAC (limited to 1000 VA) or 125 VDC (limited to 150W);
or 30 VDC when UL/CSA standard is applied;
minimum switching 100mA at 5VDC
7.1 Fixed Relay Outputs
Close CB (Generator CB Close) - Term 17 & 18

## This relay output will provide a momentary close contact when the generator is synchronised,
signalling for the Circuit Breaker to “Close”. The relay is de-energised should the generator move out
of synchronisation, or if the generator CB auxiliary contact (input 3) signals that the circuit breaker
has closed (a 1-second delay is provided to prevent "pumping" or contact racing of the breaker).
For CGC modules this relay will operate as a maintained output if a CB trip relay has not been
configured.
7.2 User Select Relay Outputs
Eight relay outputs may be configured to suit user application (RL1 to RL8). Refer to the menu
functions and all the various relay output settings and options (Set Up and Commissioning Manual).
The eight relay outputs may include switching of control functions and alarm functions. Multiple
functions/alarms can be allocated to the four combined alarm relays. Two of these “combined alarm”
functions are latched alarms/relay, and may be disabled by the Reset function.
The control functions include:

Fuel solenoid Low Inlet Pressure
At Running Speed High Inlet Pressure
Trip Generator CB Low Exhaust Pressure
Raise Voltage High Exhaust Pressure
Lower Voltage
kWatt level switch (1) and (2)
Generator CB closure (fixed output)
Speed Switches (1) and (2)
Lubricate Output **
kWatt Hour Pulse
kVAr Hour Pulse
Synchronising
Hz and Volts OK
15
In addition, up to eight (8) Modbus addresses may be allocated for the above relays, with range of
address from 4100 to 4107.
Note: AVR Motorised Operated Potentiometer (Raise Voltage & Lower Voltage)
Use one relay for raising the voltage and one relay for lowering of the voltage. This is only required if
a motor operated potentiometer is utilised OR if only logic inputs are used by the AVR for biasing.
All alarm functions can be individually set for:

i) Disabled ii) Enabled or iii) to Trip the generator CB :
this selection is displayed as [D/E/T] in the menus
The alarm functions include:

Reverse Power
High kWatt
Phase Unbalance
High kVAr
Reverse kVAr (under excitation)
Under Frequency
Over Frequency
Under Voltage
Over Voltage
Combined alarms (1) and (2)
Latched alarms (1) and (2)
DC Supply Volts Low
Gen CB Close Failure
Gen CB Open Failure
Sync – Failure & Start – Failure
Import kWatt High
Export kWatt High
Vector Disturbance (loss of utility supply whilst connected to mains)
Control Functions for the Relay Outputs:
Trip Generator CB
This relay output function is used to trip the generator CB. It is recommended that a relay output with
change over contacts (RL5 to RL8) is used for this function, to ensure a "fail safe" circuit breaker
trip signal upon a momentary CB switching operation (terminals 17 & 18 are fixed for the “close CB”
signal). Note that when a relay is allocated for the “Trip Generator CB”, the “Close CB” relay output
will operate as a momentary close signal. For momentary operation the close signal will remain while
in synchronisation and for a period of 1 second after the CB has closed. However, if the “Trip
Generator CB” relay is not allocated, the “Close CB” relay operates as a maintained close signal.
If configured, the “Trip Generator CB” output energises upon the powering up of the Si-TEC Xtend
module. The output de-energises when issuing a trip signal (during a shutdown sequence) and
remains de-energised until the generator CB aux. (input 3) goes from “High” to “Low”. The trip output
then reverts to the energised state. The output also de-energises when the Si-TEC Xtend module
power supply (24 Vdc) is removed.
It should be noted that the “Trip Generator CB” will not open (de-energise) during a sequence
shutdown if the module is under "Manual" mode, since this mode does not permit automatic changing
of the mode of the module. In addition, the alarm functions of the module may be selected to operate
the “Trip Generator CB” relay output, if required (eg Reverse Power).
Fuel Solenoid
The “Enable Run” input (input 1) should be closed (“High”) when the turbine is required to start. This
relay output function may be used in conjunction with opening the Main Steam Valve when a start
signal is issued. Should the “Enable Run” input go “Low”, the “Fuel Solenoid” relay will de-energise
immediately to close the Main Steam Valve and trip the turbine.
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Raise Voltage / Lower Voltage
These outputs are used where an AVR with MOP interface (or AVR requiring logic inputs) is utilised.
It is recommended to utilise the Si-TEC Xtend analog AVR bias interface for AVR voltage trimming
(not the relay raise/lower volts) wherever possible.
kWatt Level Switches (1) and (2)

There are two separate kWatt level functions. Each function has a “kWatt Switch ON level” (based on
a percentage of the rated kWatts) after an adjustable “ON Delay” and a “kWatt Switch OFF level”
after a separate adjustable “OFF delay” time has expired. This facility may be utilised for load
switching (sequence On/Off) of a lagging generator in a two-generator “Islanded” installation, etc. The
relay output contact closes when the actual kWatt load is above the ON preset level after the ON
preset time period (delay). The output contact opens when the actual kWatt load is below the OFF
preset level after the OFF preset time period (delay). This provides a completely adjustable ON/OFF
switching operation with a user set hysteresis (eg ON at 90% and OFF at 80%).
At Running Speed
This relay output contact closes when the turbine operating speed is above a preset speed for a
preset period of time. Typical settings are 1460 RPM (menu 592) and 3 seconds (menu 593) for a
rated speed of 1500 RPM. The speed settings are adjusted via the menu selection. This relay
output is not intended for, and must not be used as a turbine speed protection device.
Speed Switch (1) and (2)

The switching speed and time delay are separately adjustable for each of the speed switch functions.
The relay output energises on speed rise. Speed settings are adjusted via the menu selection. This
relay output is not intended for, and must not be used as a turbine speed protection device.
kW Hour Pulse and kVAr Hour Pulse

Relays can be assigned to pulse to user adjustable consumption levels.
(e.g. pulse every 10kWh - 100kWh - 500kWh etc). The pulse on time is also adjustable.
Synchronising
This relay output contact closes when the generator is in “Synchronising” state ONLY. Upon changing
of state, the output will de-energise (open). It is important to note that this function does not apply
when the “Re-sync to Grid” is enabled, as the generator CB must be open under this condition. Also,
the “Auto” input must be closed or ON and the “Sequence Hold” input must be open or OFF.
Hz and Volts OK
This relay output contact closes when the generator frequency and voltage (all 3 phases) are within
the desired limits of operation. This corresponds to frequency range limits (menu items M293 and
M294) and voltage range limits (menu items M298 and M299). Refer to “Set Up and Commissioning”
manual for details. If any of these limits are exceeded, the relay output will de-energise (open).
Low Inlet Pressure

This function will activate when the measured inlet steam pressure (analog input 4-20mA function)
reaches its minimum level and after a preset delay timer.
High Inlet Pressure

This function will activate when the measured inlet steam pressure (analog input 4-20mA function)
reaches its maximum level and after a preset delay timer.
Low Exhaust Pressure

This function will activate when the measured exhaust steam pressure (analog input 4-20mA
function) reaches its minimum level and after a preset delay timer.
High Exhaust Pressure

This function will activate when the measured exhaust steam pressure (analog input 4-20mA
function) reaches its maximum level and after a preset delay timer.
17
Alarm Functions for Logic Relay Outputs
Reverse Power (operates in a "fail safe" mode)

## This relay output energises on power up, and de-energises on Reverse Power. This provides a
“fail safe” operation for the reverse power function.
(The default setting for reverse power is 5% rated kWatt and 3.0 sec delay [max 25 sec])
High kWatt
This relay output energises when the kWatt level has been above the set alarm value for a preset
time. The relay de-energises immediately when the kWatt level falls below the “High kWatt” set point.
Phase Unbalance
Relay energises when the “kWatt 3-phase Unbalanced” level is above the set alarm value for a preset
time. The relay de-energises immediately when the level falls below the “kWatt 3-phase Unbalanced”
set point.
High kVAr
This relay output energises when the kVAr level has been above the set alarm value for a preset
time. The relay de-energises immediately when the kVAr level falls below the “High kVAr” set point.
Reverse kVAr (Under Excitation)

This relay energises when Reverse kVAr level has been above the set alarm value for a preset time.
The relay de-energises immediately when the reactive power falls below the reverse kVAr set point.
Under Frequency
This relay output energises when the frequency is below the alarm set point for a preset time. This
function is “armed” when the generator achieves the rated speed after start up.
Over Frequency
This relay output energises when the frequency is above the alarm set point for a preset time. This
Under Voltage
The relay energises when the generator voltage is below the alarm set point for a preset time. This
Over Voltage
The relay energises when the generator voltage is above the alarm set point for a preset time. This
DC Supply Volts Low

This relay energises when the 24Vdc Supply voltage is below the alarm set point for a preset time.

The “Dead Bus Timeout” alarm activates after the initial Si-TEC Xtend unit fails to issue a successful
dead bus closure. This alarm needs to be configured as part of a “Combined Alarm” relay output.
Gen CB Close Failure – Enable Alarm [Y/N]

The “Gen CB Close Failure” alarm activates if the Gen CB Aux. input fails to close (or go “high”) after
the “Close CB” relay output energises for more than 1.0 seconds. This alarm (if enabled) needs to be
configured as part of a “Combined Alarm” relay output.
Gen CB Open Failure – Enable Alarm [Y/N]

The “Gen CB Open Failure” alarm activates if the Gen CB Aux. input fails to open (or go “low”) after
the “Trip CB” relay output energises for more than 1.0 seconds. This alarm (if enabled) needs to be
configured as part of a “Combined Alarm” relay output.
Sync. Failure
This relay energises when the generator has failed to synchronise after the preset time.
18
Start Failure
The relay energises when the turbine has failed to start after the start sequence input (input 2) has
been switched “High”.

The relay energises with the failure of a MPU. This alarm is activated should the MPU signal fail
during operation, and is not activated with a stationary turbine. The MPU “fail safe” operation when
starting and a secondary redundant MPU/Proximity Switch provide for a very high level of integrity
with the speed sensing system.
Vector Disturbance (loss of grid supply)

Relay energises when a loss of 3-phase Mains/Grid supply and/or a vector phase unbalance (in
kWatt) are detected. The vector phase unbalance alarm (incorporated within the Vector Disturbance
relay output) differs with the “Phase Unbalance Alarm”, as this is based on dynamic conditions (rate
of change of kWatt), whereas the “Phase Unbalance Alarm” is based on steady state or static
conditions. In order for the “Vector Disturbance” relay to operate, the generator must be paralleled
with the Mains/Grid to sense this failure.
All alarm points may be allocated to an output relay. Refer to the relay configuration detail. Any relay
may also be assigned to be switched from a combination of user selected alarms.
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8. ANALOG INPUTS
All the 4-20 mA analog inputs AI-1, AI-2 and AI-3 may be configured to suit user application. Refer to
the menu functions and preset values (Set Up and Commissioning Manual) for further analog input
setting and options. AI-4 is designated for a RTD signal. The following list is a description of the
analog input referencing functions available.
All analog input functions are allocated to be referenced from the “Preset Value”, AI-1, AI-2, AI-3, AI-4
or from the CAN BUS AI-5, AI-6, or from a “Modbus” address. They are as follows:
High Modbus Ref. Value

The menu item “High Modbus Ref. Value” provides for the setting of decimal values representing the
‘Maximum Reference’ or 100% value for that input function (in lieu of the analog 4-20mA). For
example if the maximum (100%) communicated value was a 12 bit number this would be set at 4095;
and for a 16 bit capacity, set at 65535. The Si-TEC Xtend module then scales the input value for the
input function references.
The Modbus Analog Inputs AX0 – AX7 correspond to the Modbus Write Addresses 4000 – 4007
respectively, and may be used as a source for the following Analog Input Functions:
kWatt Control [BL#2] Inlet Pressure

kWatt Limit (Grid) Exhaust Pressure
kVAr Control (Grid) Process Reference
PF Control (Grid) Process Measurement
Warm Up Speed Spare 1
Import kWatt Sensor Spare 2
Minimum Import kWatt Setpoint kWatt Simulated PV
Temperature (RTD) (AI-4) Source

This sets the source for the temperature sensor (RTD PT100) input.
kWatt Control [BL#2] –

This is used to set the kWatt reference for a generator paralleled to the utility (grid) supply operating
without a master GSM module, and for a remote adjustable “Base Load” kWatt reference control.
(refer to page 11 for “kWatt control priority”).
kW Limit Control (Grid) –

This is used to provide a limiting point for the generator kWatt. A kWatt limit has priority over all kWatt
references, whether by a master GSM module, preset reference value or kWatt control 4-20mA input.
kVAr Control (Grid) –

This is used to set the kVAr reference for a generator paralleled to the utility (grid) supply operating
without a master GSM module, and for a remote “Base Load” kVAr reference control where a variable
reference is required over the preset PF references.
PF Control (Grid) –
Used to set the Power Factor reference for a generator paralleled to the utility (grid) supply operating
without a master GSM module, and for a remote “Base Load” Power Factor reference control where a
variable reference is required over the preset PF references.
Warm Up Speed –
The speed for warm up of a turbine, prior to synchronising, can be varied with this input function.
Import kWatt Sensor –

This 4-20mA input is for a bi-directional kWatt transducer on the incoming supply from the utility grid.
The input signal representing Import/Export kWatts provides for a Minimum import (or Maximum
Export) kWatt level.
20
Minimum Import kWatt Set point –
This 4-20mA input provides the generated power to be referenced to maintain a variable
Import/Export kWatt level. A preset value may be used if a variable reference is not required. To
operate this function a bi-directional kWatt transducer(s) for the incoming supply must be installed.
Inlet Pressure –
This 4-20mA input is from a pressure transmitter measuring inlet pressure from supply steam to
turbine.
Exhaust Pressure –
This 4-20mA input is from a pressure transmitter measuring exhaust pressure of the turbine.
Process Reference –
This sets the process reference for a generator paralleled to the supply grid, provided that the
“Enable Process Control” input and the “Process Ref. Analog” input are switched “High”.
Process Measurement –
This 4-20mA input is from a pressure transmitter measuring a process PV (eg. exhaust pressure).
Spare 1 –
This 4-20mA input is from a sensor or transducer.
Spare 2 –
This 4-20mA input is from a sensor or transducer.
kWatt Simulated PV –
This 4-20mA input is from a kWatt transducer or a simulated signal representing generator kWatts.
The terminals for the analog inputs are:
AI-1 4-20mA Input - Terminals: 37- & 38+ (shield: 36)

This may be configured for user requirement (e.g. kWatt Reference, Limit, etc).
Internal resistance of the input is 62 Ω.

This may be configured for user requirement (e.g. kWatt Reference, Limit, etc).
Internal resistance of the input is 62 Ω.

May be used as 0-5 volt by jumper selection.
Configured for user requirement (e.g. kWatt Reference, Limit, etc ).
Internal resistance of the input in 4-20mA mode is 240 Ω.
Analog Inputs are transferred via the “Modbus” communications as scaled "raw" values.
i.e. 0 = 0mA , 48 = 4 mA and 255 = 20.9mA
AI-4 RTD Input - Terminals: 46- & 47+ (shield: 45)

Consult the manufacturer (Dawson Technology) for options available before using this input.
Analog input hardware specification:
If the analog input is externally referenced to the 24Vdc supply, the voltage input range must be
within the 24Vdc power supply range supplied to terminals 93 and 94 of the Si-TEC Xtend module.
The internal resistance for AI-1 and AI-2 is 62 Ω, while AI-3 is 240 Ω.
Note: It is essential to adopt standard instrumentation practices with regards to cabling, noise
interference and isolation. Use a line isolator if the external supply for the analog input exceeds the
nominal 24 Vdc range.
21
9. ANALOG OUTPUTS
All three 4-20mA analog outputs may be configured to suit user application. Refer to the menu
functions and preset values for further analog output setting and options (Set Up and Commissioning
Manual).
Analog output hardware specification:
Each analog output may drive into a maximum total burden of up to 500Ω, for a total voltage output
requirement not exceeding 10 V (series 4-20 mA devices with the analog output).
The 4-20 mA outputs (current sink) are referenced from the 24 Vdc positive supply. If the driven
device (eg PLC, DCS, etc.) is referenced to a negative supply, a line isolator will be required.
Note: Adopt the normal and standard instrumentation practices with respect to cabling and noise
interference. Also, terminal nos. 64, 67 and 70 are 24 Vdc (+) source from the Si-TEC Xtend 3A fuse.
The terminals for the Analog Outputs are:
A0-1 A0-2 A0-3

Shield 62 65 68
Positive (+) 63 66 69
Negative (-) 64 67 70
The 4-20mA analog outputs may be selected from the following:
Turbine Speed -
4mA = preset value 20mA = preset value
Actuator Position % -
Generated kWatt – (range includes for negative kWatt)

Generated kVAr – (range includes for negative kVAr)

Generator Power Factor – range is adjustable in units, not power factor

4mA = preset value (in units - typically 0) : 0 = 0.50 PF leading
20mA = preset value (in units - typically 10000) : 10000 = 0.50 PF lagging
(Note: The scaling of the power factor meter must be linear)
The Si-TEC Xtend module provides for adjustable and reverse range scaling of the power factor
meter.
Examples:
Meter Scaling set preset unit values to
4mA - 20mA 4mA @ 20mA @
0.50 lead 0.50 lag 0 10000
0.70 lead 0.70 lag 2000 8000
0.50 lag 0.50 lead 10000 0
0.80 lead 0.40 lag 3000 11000
0.30 lead 0.20 lag - 2000 13000
Import kWatt Sensor - (negative for Export kWatt)

22
Final kWatt Set Point - (range includes for negative kWatt)
The target kWatt load of the generator.
Inlet Pressure -
Exhaust Pressure -
Process Reference -
Process Measurement -
Spare 1 Output -
Spare 2 Output -
23
10. ANALOG AVR BIAS OUTPUT
The analog AVR Bias Output for trimming the AVR provides a voltage bias signal (adjustable range to
suit numerous AVRs from – 8.4V to + 8.4V) for generator voltage adjustment.
The terminals for the AVR bias are:
Output: Terminal 71
Return: Terminal 72
Shield: Terminal 73
Refer to the Si-TEC Xtend “Set Up and Commissioning Manual” for further information on analog
AVR trimming as well as details of AVR connections for various manufacturers.
Note: To prevent the occurrence of any current overload (maximum of 75 mA), the minimum load
impedance for the AVR bias output should be 120Ω. Hence, if the load impedance of the AVR
terminal connections is less than 120Ω, it will be necessary to limit the current by introducing a
corresponding value resistor in series between terminal 71 (of the Si-TEC Xtend module) and the
AVR bias terminal. Please contact the AVR manufacturer for more details of the AVR terminal
impedance.
Example: If the AVR bias terminal impedance (measured when the AVR power supply is removed) is
20 Ω, it will be necessary to introduce a resistor of at least 100Ω in series between terminal 71 of the
Si-TEC Xtend module and the AVR bias terminal.
For further details on interfacing with various AVR types and models, please refer to section 6.3 of the
Si-TEC Xtend Set Up and Commissioning Manual (ref no 549-023 rev D).
24
11. TURBINE GOVERNING CONNECTIONS
Actuator connections
StG (all-electric) Actuator – standard for most Si-TEC Xtend control systems
Actuator Output: 77: red (B), 76: black (C).
Actuator Feedback: 58: shield, 59: signal or yellow (A), 60: 0V or blue (E), 61: ‘+’ or red (D).
OEM and other Actuators (4 – 20 mA, 0 – 20 mA, 0–200 mA, 0 – 5 Vdc, +/- 10 Vdc) {feedback
input is not used here}
Negative: terminal 77
Positive: terminal 76
Shield: terminal 75
Note: The 4–20mA and 0–5V driver outputs may be used for interfacing with various actuators used
as part of the turbine manufacturer’s control systems. The 0–200mA driver outputs are typically used
for most Woodward electro-hydraulic actuators. Additional driver outputs are available for specific
governor / turbine applications. Please contact Dawson Technology for further details.
Speed Sensor Connections
Magnetic Pick Up 1 terminals 82: shield, 80: black, 79: red.

or Proximity Switch terminals 82: shield, 81: -, 78: +, 79: signal
Magnetic Pick Up 2 terminals 87: shield, 85: black, 84: red.

or Proximity Switch terminals 87: shield, 86:-, 83:+, 84: signal
25
12. VOLTAGE AND CURRENT SENSING
12.1 Voltage Sensing Inputs – Generator & Bus/Grid
The Si-TEC Xtend is software selected for voltage input range.

Range “0” should be selected for nominal voltage of 63.5 Vac Ph/N, while range “1” is for a nominal
voltage of 240 Vac Ph/N. For a nominal voltage of 120 Vac Ph/N, range “1” should be used.
Generator Volts (up to 600 Vac phase to phase direct connection)

104 (Aφ) red phase, 105 (Bφ) white phase, 106 (Cφ) blue phase, 107 (N) neutral.
Bus Volts (up to 600 Vac phase to phase direct connection)

100 (Aφ) red phase, 101 (Bφ) white phase, 102 (Cφ) blue phase, 103 (N) neutral.
NOTE: The “Star Point” for the voltage input is not essential for PT supplied 110 Vac
phase/phase voltage sensing. However, it is recommended that the neutral of the direct
voltage sensing systems be connected to the Si-TEC Xtend Neutral terminal.
12.2 Current Sensing Inputs - Generator
Generator Output Current (true RMS) is sensed from 5 Amps or 1 Amp secondary current
transformers (CTs). The burden required from CTs is less than 0.1 VA.
With P1 of the CTs facing the generator:

Terminal Terminal
(Aφ CT) red phase 108 – S1 109 – S2
(Bφ CT) white phase 110 – S1 111 – S2
(Cφ CT) blue phase 112 – S1 113 – S2
Neutral CT optional 114 – S1 115 – S2
NOTE: Current transformer terminals are fixed terminals unlike all other terminals that are of the
plugable or removable type. Refer to the typical wiring diagram for current transformer
connection detail.
26
13. POWER SUPPLY
24 Volts NEGATIVE (nominal) terminal 94

24 Volts POSITIVE (nominal) terminal 93
Shield or Earth (optional) terminal 95
NOTE: Supply voltage is nominally 24 Vdc however the controller will operate from between a low
level of 22 Vdc to 30 Vdc. Normal voltage requirement being 24 Vdc ± 10%
The current drawn by each Si-TEC Xtend system is subject to the type and loading of the actuator.
The typical current drawn by the Si-TEC Xtend module is < 0.8 Amp + actuator current. A 10 amp
(separately fused) supply for each Si-TEC Xtend module should be provided. If utilising a battery
charger and battery supply, it is advised that the battery charger should also be suited to operate as a
power supply and must not produce voltage spikes in the event of the battery leads being
disconnected.
Typically, the recommended 24 Vdc battery supply (at least 18 Ah rating) would be “Sealed Lead–
Acid” (Dry Cell) type, for extended life and lower maintenance. Typically, these may either be AGM
(Absorbed Glass Mat) type or Gel Cell type sealed lead-acid batteries. For battery charger, a 24 Vdc
(at least 15A) Switch Mode battery charger cum power supply (with temperature compensation)
would be strongly recommended. Please contact Dawson Technology for any further details.
27
14. RS485 and RS232 COMMUNICATIONS
14.1 RS485 Si-TEC LAN - Terminations
52: (LAN B) black core, 51: (LAN A) red core, 50: (Common) white core, 49: Shield, 48: Ground
Loop RS485 cable between Si-TEC Xtend modules from terminal with the same numbers.
(i.e. 52 to 52 to 52 etc. - 51 to 51 to 51 etc. - 50 to 50 to 50 etc.)
Note 14.1:
(1) Cable requirement : 3 core 0.5mm twisted. Use Dawson Technology RS485 cable part number
660-040.
(2) A 120Ω terminator is required at each end of the RS485 communications loops (between
connections A and B). The terminator is Si-TEC Xtend part no. 444-303 (white).
(3) Cabling must loop directly from module terminals and with NO “TEE Offs”.
(4) Shielding for communications loop to be grounded at one end only (terminal 48).
(5) Maximum total loop length is 1200 metres, with up to 24 Si-TEC Xtend modules connected within
the loop network.
14.2 RS485 User LAN - Terminations
LAN B LAN A Common Shield Ground

Si-TEC Xtend: 88: (B) black 89: (A) red 90:common 91:shield 92:ground
Isonet converter: RXD- & TXD- RXD+ & TXD+ GND not Used not Used
Cescom converter: Rx- & Tx- Rx+ & Tx+ TCR not Used not Used
Electrex RS485: 20 19 18 not Used not Used
Loop RS485 cable between Si-TEC Xtend modules from terminal with the same numbers and other
devises with the corresponding termination. Refer to the above cable requirement (Note 14.1) for
details.
For example:
Isonet RS232 to RS485 Converter Si-TEC Electrex RS485
Core 1: RXD- & TXD- TO 88 to 88 to 88 etc TO 20 to 20 to 20 etc
Core 2: RXD+ & TXD+ TO 89 to 89 to 89 etc TO 19 to 19 to 19 etc
Core 3: Common TO 90 to 90 to 90 etc TO 18 to 18 to 18 etc
Shield: Not Connected TO 91 to 91 to 91 etc TO Not Connected
14.3 RS232 Communications / Diagnostics Port
The RS232 communication port is a 9 pin female “D” connector.

The cable pin out being 2 to 2, 3 to 3 and 5 to 5. (no cross overs)
For typical PC com1 port to Si-TEC Xtend RS232 connection, use a 9 pin “D” extension cable (male
to female).
14.4 CAN BUS - Terminations
57: (CAN H) black core, 56: (CAN L) red core, 55: (Common) white core, 54: Shield, 53: Ground
Refer to the above cable requirement (Note 14.1) for details. Maximum cable loop length is 125 m.
14.5 Interface with Dymec Fibre Optic Links (Half Duplex)
Si-TEC LAN terminals User RS485 LAN terminals Dymec 25 pin “D” terminals
50 90 7
51 89 2&3
52 88 14 & 16
28
15. INSTALLATION NOTES
## 1. Mounting of Si-TEC Xtend control module.
• The Si-TEC Xtend unit is to be mounted in vertical plan (+/-25o as referenced to the Xtend
backing plate) on the sheet metal panel inside standard switchboard cubicle.
• In order to provide efficient heat dissipation the minimum recommended mounting panel area
should be at least 0.25 m2 (2.5 sq. feet) per Xtend unit or approx. twice the unit footprint area.
• The internal cubicle volume should be at least 60L (approx. 2 cubic feet) per Xtend unit for still
air. For the forced air cooling it could be 50% of the above.
• The mounting panel should preferably be of galvanised finish.
• To tap the holes for the M6 screws provided, mounting panel thickness has to be at least 2.5mm.
• The mounting location of the Si-TEC Xtend module should protect unit from direct exposure to
water or to condensation-prone and/or corrosive environments.
• The mounting location should meet requirements of the UL508 Pollution Degree 2 - normally,
only nonconductive pollution occurs.
• Adequate ventilation should be provided in order to keep ambient air temperature inside cubicle
below +60o C.
• The Si-TEC Xtend control module must not be mounted on the turbine or close to heat sources.
## 2. Generators / alternators should be fitted with the manufacturer's standard CT droop kits when
utilising the Si-TEC Xtend AVR voltage trimming facility, whether using the analog biasing or bias via
a MOP. (A range of MOPs is available from Dawson Technology if this is required)
## 3. On applying a 24Vdc (10 Amp fused) supply to terminals 94- & 93+, the assigned “Reverse
Power” relay will energise. The relay de-energises upon a reverse power or a loss of supply voltage.
## 4. Use a separately fused supply from the Si-TEC Xtend control module supply for the operation
of the “Reverse Power” and the “Trip Generator CB” relay output signals. Should the Si-TEC Xtend
module fuse “blow”, a positive supply will still be maintained for the “Reverse Power” signal operation.
## 5. Install a ground (earth) wire (size: 2.5mm) from the Si-TEC Xtend ground stud to a
“clean” instrument earth bar. It should be noted that the ground (earth) terminals of the Si-
TEC Xtend module i.e. terminals 48, 53, 75, 92 and 95 are linked internally to the Si-TEC Xtend
ground stud.
## 6. Most terminals for shield wiring for the Si-TEC Xtend are linked to earth (Si-TEC Xtend ground
stud). These include Analog Inputs, Analog Outputs, Actuator Feedback, AVR Bias and MPU. The
only shield terminals NOT linked to earth are terminals 49 (Si-TEC LAN), 91 (Customer LAN) and 54
(CAN Bus). The shields are floating and need to be looped directly from module to module. At ONE
end of the loop, the shield terminal should be looped to ground terminals 48 (Si-TEC LAN), 92
(Customer LAN) and 53 (CAN Bus) respectively. Please refer to the LAN wiring interface diagram.
## 7. The logic inputs will operate from 9V to 36Vdc continuous, however 24Vdc is recommended.
## 8. Logic Input 1 (Enable Run) should be interlocked with a turbine emergency shutdown device.
(e.g. over speed, high temperature, ground fault, etc). Input 1 should remain energised when
performing a normal shutdown of the turbine-generator.
## 9. Logic Input 2 (Start Seq.) should be interlocked with a generator “Over-current Trip” relay,
“Reverse Power” protection or similar trip functions, and remain de-energised until the fault has been
reset. This will prevent the generator from re-synchronising, and will provide turbine shutdown
following the cool down period.
## 10.The “Trip Generator CB” relay output and the “Reverse Power” relay output operate in a “fail
safe” mode. The relays de-energise to the “Trip Generator CB” and “Reverse Power” relay alarm
during a trip, and upon the loss of the Si-TEC Xtend 24 Vdc power supply.
## 11.When using the “Reverse Power” relay output as a function within a “Combined Alarm”, the
“Combined Alarm” relay output will energise on a fault condition.
29
16. ADDITIONAL SYSTEM OPTIONS
The Si-TEC Xtend GSM (Generator System Master) control module is available for comprehensive
Import / Export control and extensive referencing of generator system kWatts and kVAr, as well as for
grid synchronising or bus-to-bus synchronising. A “True Time Error Correction” GSM control option is
also available for islanded operating power station applications. This option provides for a single
station setting for set point voltage and frequency, and will perform the correction of time error to
within an accuracy of less than one minute per year.
The Opal Generator Annunciator provides a remote display of the Si-TEC Xtend control (via the
CAN BUS port) that may be door mounted for ease of operator monitoring. In addition, it also
provides accurate metering display of generator parameters (including Frequency, Voltage, kWatts
and Power Factor), as well as Overspeed protection features. The Opal Annunciator may also be
extended to conduct accurate monitoring of critical turbine parameters (including Lube Oil pressure,
Inlet Pressure, Exhaust Pressure, Control Supply Voltage, etc.), providing turbine monitoring and
protection that integrates with the Si-TEC Xtend CGC control system.
pcConfigure software (Windows® based)

This software tool facilitates easy menu configuration, up-loading, down-loading, storing and printing
of all Si-TEC Xtend control menu session files. The session files may also be sent via e-mail back to
the manufacturer for remote assessment and technical support.
pcTune software (Windows® based)

This software provides real time analysis of load transients, along with tuning of the speed governor
and generator dynamics, and operates on a 20 ms scan time (adjustable) for up to 16 selected data
points. The selection can be made from an extensive choice of data registers. The pcTune software
also provides interface feature via the Internet (ADSL) which allows the diagnostics and tuning of the
Si-TEC Xtend control to be conducted remotely (eg. from our factory), if required.
pcDataView software (Windows® based)

This software provides data logging, trending and event logging of the Si-TEC Xtend system network.
The system covers turbines, generator and Grid incomer data.
30
17. Si-TEC XTEND CGC & GSM VECTOR DISTURBANCE RELAY DESCRIPTION
The vector disturbance relay allows rapid detection of the loss of mains supply by a paralleled Si-TEC
Xtend CGC (or GSM) unit. This is possible through the detection of a small change in the generator
voltage vector angle relative to the rotor mechanical position. For the vector angle change to occur as
a result of the loss of mains, the load on the generator must change by a specific amount depending
on the sensitivity setting. It is important to note that the operation of the vector disturbance relay does
not depend on frequency deviation or voltage amplitude variations.
The relay detects the vector disturbance within 2 cycles (40ms) of the mains (grid) separation,
allowing the generator connection to the mains to be tripped well before mains power system
automatic re-closure occurs (typically 200 ms to 5 secs after trip).
The one condition that the relay cannot detect is a mains separation when the load on the generator
side of the separation point is such that the generator set sees little or no load change. In most
power systems, this situation is unlikely. Should this occur, the vector disturbance relay activates if
and when the load attached to the generator changes sufficiently to cause the requisite vector angle
change.
The relay sensitivity setting is the vector angle change required to activate the relay, and is adjustable
via the Si-TEC Xtend keyboard from 1 degree to 15 degrees in 1 degree increments. Approximate
load changes required to cause vector disturbance magnitudes are listed below.
Vector Disturbance Degrees % Rated Load Change
1 5%
2 15%
5 35%
10 70%
The sensitivity adjustment is normally set to 5, which give the best compromise between a nuisance
tripping and detection coverage. The setting may be reduced to 1 degree in areas without ripple
voltage control systems, which at high amplitudes can cause apparent vector disturbances of up to 1
degree.
This relay provides protection from transmission system faults, where the mains voltage may be
absent or reduced for a significant period of time before the fault is cleared. Operation of the relay
and subsequent disconnection of the generator from the mains prevents possible loss of synchronism
("pole slipping" or "out of step" operation) after the fault is cleared. When the fault occurs the system
impedance as seen at the generator terminals changes, with both real and reactive components
normally decreasing. The impedance change causes a rapid generator loading change and voltage
vector change, triggering the relay. In the unlikely circumstance of the impedance change being
gentle enough that the relay is not triggered when the fault occurs, then should pole slipping occur
when the fault is cleared, the violent load changes associated with pole slipping are guaranteed to
trigger the relay.
The vector disturbance relay is further energised upon the loss of a single or two phases. This is
achieved by utilising differential phase sensing of kWatts.
31
18 Si-TEC Xtend Communication Addresses accessed from RS232
Communications Port and User RS485 Port (2000-address range)
The Si-TEC Xtend User RS485 port settings are as follows:

Menu 142
Bit Mode Data Bits Parity Stop Bits
ASCII 0 7 N 1
ASCII 1 7 E 1
ASCII 2 7 O 1
ASCII 3 7 N 2
RTU 4 8 N 1
RTU 5 8 E 1
RTU 6 8 O 1
RTU 7 8 N 2
Baud rates of 19200, 9600, 4800 and 2400 are supported on the User RS485 port.
The optional “User RS485” port supports both “MODBUS” ASCII and RTU protocols, and supports
both read and write functions for extensive addressing of the Si-TEC Xtend module. The addressing
supported includes for that detailed below, menu preset values, and selected diagnostic data points.
The Si-TEC Xtend modules are a slave device on the Modbus network and do not function as a
communications Modbus master.
The Si-TEC pcTune program may only access the Si-TEC Xtend set points via the RS232 port. It is
strongly recommended that the Si-TEC Xtend RS232 port be utilised for generator diagnostics only.
The “User RS485” communications port should be used for interfacing to Programmable Logic
Controllers, SCADA Systems and the like.
The Si-TEC Xtend modules’ communication facility includes for numerous Modbus error message
codes, exception codes 01, 02, 03, 04, 05, 06 and 08. When writing to a slave Modbus device the
“reply” from the slave device should be checked for error codes. Most Modbus propriety drivers
include for adequate error checking and data handling. Should it be necessary to write a Modbus
driver it is essential that the driver includes as a minimum; return function code “bit 7” is not set,
checksum (ASCII) or CRC (RTU) error checking, string length and end character checks, time out
control, error checking and detection of Modbus exceptions, disposal of “bad data packets”, and
buffer clearing.
It should be noted that the master module data address points differ with the generator modules.
Use Modbus function 3 for reading of data – typical start address of 2000 for operational data.
Use Modbus function 16 for writing data – refer to the following list for write addresses.
Use Modbus function 6 for single writes.
The Si-TEC pcTune and pcTransient programs only function on the Xtend module RS232 port. The
Si-TEC pcTune also operates via a modem connection (for off site Tuning and Diagnostics).
The Si-TEC pcConfigure typically operates from the Xtend RS232 port, although it can also operate
from the User RS485 port (applies to pcConfigure ver. 1.34 onward).
The User RS485 must be configured as follows for the pcConfigure communications.
a) Set pcConfigure communications for the correct slave (node) - menu 137
b) RS485 mode - set to ASCII - menu 138
c) User RS485 W.Endian - set to 0 = big - menu 140
d) User RS485 Bit Mode - set to 4 (8N1) - menu 141
The Generator module “User RS485 Address” (menu 137) is the node to address for the respective
generator not the generator module # (menu 132).
32
Special write addresses: write is Modbus function 16
Operation Address Data
Open access to write 5503 200
Reset Alarms 5501 200
Store 5509 47931
Special menu functions

Function Menu Operation
Abort all changes – back to EEprom settings 866 Push Reset Button
Data at Modbus address 087 Select addresses + / -
CPU load 088 Display only
Variables changed and not stored 013 Scroll through – Direct GoTo
Reset Accumulated Data –

a) Requiring to be in technical access mode first – resets all the following
Reset kWatt Hour, kVAr Hour, Run Hours, No of Starts, Times powered Up/Down
Address 5501 (reset address) data value of 10202
b) To reset the following accumulated data to zero – user access is required

Operation Address Data
Resets kWH and kVArH 5501 10370
Run Hours 5501 10444
No. of Starts 5501 10568
Remote Alarm Reset 5501 200
c) The above accumulated data values can be edited using the Si-TEC pcConfigure
program This enables modifying data should turbines or modules be relocated, replaced,
etc.
Please refer to the 2000 address listing for reading of the data items, with the exception of the
No. of Starts which is read at address 5653.
PLD Type
Read address 5951
Data of 254 is OLD PLD (pre Dead Bus) : Data 29 is NEW PLD including Dead Bus
33
18.1 Generator Module Address (offset) Data Reference
2000 Range Data Item Remarks

Address
2000 Multiplier for kWatt, kVAr, and Voltage (refer to table)

2001 Generator State (refer to state table)
2002 K Generator kWatt (F)
2003 K Generator kVAr (F)
2004 K Generator Rated kW (F)
2005 Generator RPM
2006 Desired Actuator Percent
2007 Feedback Actuator Percent
2008 Analog Input 1 (in 0.01 mA)
2010 Communications Time Out (0-31)
2011 Average Current (F)
2012 V Average Generator Voltage (ph/n) (F)
2013 V Average Bus Voltage (ph/n)
2014 Logic Status 1,2 (refer to status table)
2015 Alarm 1 Functions (refer to alarm 1 table)
2017 Control Battery Voltage
2018 Analog Input 4 (RTD in °C)
2020 Logic Input 1 – function inc. Modbus (refer to logic input 1 table)
2021 Logic Input 2 – function inc. Modbus (refer to logic input 2 table)
2022 K Generator kWatt A phase (F)
2023 K Generator kWatt B phase (F)
2024 K Generator kWatt C phase (F)
2025 Generator Current A phase (F)
2026 Generator Current B phase (F)
2027 Generator Current C phase (F)
2028 V Generator Volts A phase (F)
2029 V Generator Volts B phase (F)
2030 V Generator Volts C phase (F)
2031 Not Used
2032 Generator Frequency (F)
2033 Generator Power Factor
2034 No. of Turbine Starts
2035 Bus Frequency (F)
2036 K Generator kVAr A phase (F)
2037 K Generator kVAr B phase (F)
2038 K Generator kVAr C phase (F)
2039 Gen CB - Last Trip Cause
2040 Turbine Run Hours 32 bit (lower 16 bit)
2041 (upper 16 bit)
2042 kWatt Hours 32 bit (lower 16 bit)
2043 (upper 16 bit)
2044 kVAr Hours 32 bit (lower 16 bit)
2045 (upper 16 bit)
2046 Sync. Phase Error
2047 Slip Frequency
2048 K Desired kWatt
2049 K Desired kVAr
2050 K Minimum Control kWatt
2051 V Bus Volts A phase (F)
2052 V Bus Volts B phase (F)
2053 V Bus Volts C phase (F)
2054 AVR Biasing Voltage (in 0.01V)
34
2055 AVR Biasing % (in 0.1%)
2056 Logic Input Function – at Terminal - excluding Modbus Status
2057 Logic Input Function – at Terminal - excluding Modbus Status
2058 Logic Hardware Input Status (inputs 1 to 16)
2059 Relay Output Bit Status (relays 1 to 8)
2060 Lube Oil Pressure – Opal
2061 Exhaust Pressure – Opal
2062 Inlet Pressure – Opal
2063 Analog Input 3 – Opal
2064 Control Volts - Opal
2065 Logic Status 1 – Opal
2068 Turbine Speed – Opal
2069 CAN Bus Logic Inputs – 1 to 16
2070 Logic Input 3 – function includes Modbus
2071 Logic Input Function 3 at Terminal – excluding Modbus status
2072 HP Actuator Current (F)
2073 Speed / kW Demand % (before Limits & Linearization)
2074 Inlet Pressure – CGC
2075 Exhaust Pressure – CGC
2076 Spare Input 1 (4-20mA)
2077 Spare Input 2 (4-20mA)
2078 Process Reference (SP)
2079 Process Measured (PV)
2080 Process PI after Limiting (in 0.01%)
2081 Process kWatt Setpoint
2082 Process Limit Bits
Notes:
K = kWatt Multiplier is used
V = Voltage multiplier is used
(F) = Filtered value
Communication Notes:
1) kWatt and kVAr (items 2 & 3) are transmitted as 2's complement of 65536 or 16 bit.
2) Frequency (item 32) is in two decimal places (i.e. 50Hz transmitted as 5000).
3) Power Factor (item 33) is in two decimal places and is transmitted as 2's complement of 256 or 8
bit (this is to provide possible negative values).
4) The Modbus protocol provides for all data to be transmitted as word (16 bit) values.
35
18.2 Generator Module Address Offset Data Reference (6000 to 8300 range – read
only). Data available at every Si-TEC Xtend Module
Module 0 has a base address 6000, module 1 has a base address of 6100.
Increase this base address by 100 for each increment in the module number
Address Data Item BASE ADDRESS of 6000 to 8300

Offset
0 Multiplier for kWatt, kVAr, and Voltage

1 Generator State (refer to state table)
2 Generator kWatt K
3 Generator kVAr K
4 Voltage Error
5 Reference kWatt K
6 Reference kVAr K
7 Generator Rated kW K
8 Rated kVAr Lagging K
9 Rated kVAr Leading
10 Reserved (for kVA)
11 Reserved
12 Minimum Control kWatt K
15 Logic Status 1 (refer to status table)
16 Logic Input 1 (refer to logic input 1 table)
17 Logic Input 2 (refer to logic input 2 table)
18 Desired Actuator Percent
19 Feedback Actuator Percent
20 Average Current
21 Average Generator Volts ph/n V
22 Average Bus Volts ph/n V
23 Generator RPM
24 Generator Frequency
25 Generator kWatt A phase K
26 Generator kWatt B phase K
27 Generator kWatt C phase K
28 Generator Power Factor
29 Average Actuator Current
30 Generator Current A Phase
31 Generator Current B Phase
32 Generator Current C Phase
33 AVR Biasing % (in 0.1%)
34 Generator Volts A phase V
35 Generator Volts B phase V
36 Generator Volts C phase V
37 Analog Input 1
38 Analog Input 2
39 Analog Input 3
40 Analog Input 4 (RTD)
41 Reserved
42 Reserved
43 Reserved (Misc_Flags)
44 Reserved
45 Logic Input 3 – function
46 Limits Active
47 Communications Timeout (0-31)
Notes: K = kWatt Multiplier is used ; V = Voltage multiplier is used
36
18.3 Generator State Table 1 (2000 range – address offset 1)
Bottom 5 bits Reciprocating

Value
0 Alarm Shutdown
1 Genset Shutting Down
2 Genset is Shut Down
3 Start Fail
4 Pre Start
5 Pre Lube
6 Pre Barring
7 Not Used
8 Not Used
9 Warm Up 1 Speed
10 Ramp to Warm Up 2 Speed
11 Warm Up 2 Speed
12 Ramp to Idle Speed
13 Idle Speed
14 In Critical Speed Band 1
15 In Critical Speed Band 2
16 Ramp to Rated Speed .
17 Warm Up at Rated
18 Synchronising
19 Ramp Up Island Mode
20 Isolated (Island) Mode
21 Ramp Down Island Mode
22 Ramp Up Parallel to Grid Mode
23 Parallel to Grid Mode
24 Ramp Down Parallel to Grid Mode
25 Not Used
26 Overspeed Test Mode
27 Ramp to Cool Down Mode
28 Cool Down Mode
29 Not Used
30 Post Barring
31 Not Used
bits 0 - 4 is a 5 bit unsigned integer, which indicates the state (pub_state) see index below.
bit 5 is set if “Sequence Hold” input is high
bit 6 is set if “Auto” input is high
bit 7 is set if any of the following is true: base loaded, process active, actuator limited, kW
limited, under “grid droop” control, ramping On/Off load share.
bits 8 - 15 are not used, all = 0
Note: A Generator can only be in one of the 0-31 states at any one time. Addition of the value of the
upper 3 bits provides the additional information.
It should be noted that the master module (GSM) address points differ in part from the address points
of the CGC modules. The above addresses may be read from either the CGC or GSM modules for
generator data addresses. Please refer to the Si-TEC Xtend GSM manual for details of the master
data address points.
37
18.4 Generator Status and Alarm Tables (logic items)
Address Address Address
Bit Bit Value Status 1,2 Alarms 1 Alarms 2
15 32768 Reserved Reserved Turbine Speed Mismatch*

14 16384 Reserved Loss of kW Input Loss of Process Input
13 8192 Bus ACB & Sync Dead Bus Timeout Reserved
12 4096 Bus ABC & Sync Vector 3 Phase Loss Gen CB Open Fail
11 2048 Same Phase Rot. Phase Unbalance Gen CB Close Fail
10 1024 Hz & Volts OK Vector Phase Unbalance Reserved
9 512 CB Close Export kWatts High MPU 2 Failure
8 256 kWatt Level Sw 2 Import kWatts High MPU 1 Failure
7 128 kWatt Level Sw 1 Over Voltage Variable Error
6 64 Trip CB Output Under Voltage Speed Deviation
5 32 Speed Switch 2 Over Frequency Start Failure
4 16 Speed Switch 1 Under Frequency Sync. Failure
3 8 At Run Speed High kVAr MPU Failure
2 4 Barring ** Reverse kVAr DC Supply Low Voltage
1 2 Fuel Solenoid High kWatts High Actuator Feedback
0 1 Lubricate ** Reverse Power Low Actuator Feedback
* : For “Split Shaft” steam turbines

** : Not implemented yet
18.5 Generator Logic Input 1 & 2 Tables
Address Address Address
Bit Bit Value Logic Inputs 1 Logic Inputs 2 Logic Inputs 3
15 32768 Group 2 (bit matrix) Reserved Reserved

14 16384 Group 1 (bit matrix) Reserved Reserved
13 8192 Re-Sync to Grid Reserved Reserved
12 4096 kWatt De-Rate Dead Bus Mode Process Decrease
11 2048 Rated Speed Reserved Process Increase
10 1024 Synchronise Inhibit Enable Minimum Import Process Droop
9 512 Fast Rate Barring Complete ** Process Ref. Analog
8 256 Enable Load Share Reset Fault Enable Process
7 128 Sequence Hold Permissive Sync Reserved
6 64 Base Load 2 Enable Cntrl. via Comm. Reserved
5 32 Base Load 1 Hot Start Reserved
4 16 Auto - Input Over Speed Test Reserved
3 8 Mains CB Closed (i/p 4) Speed (kWatt) Decrease Reserved
2 4 Gen CB Closed (i/p 3) Speed (kWatt) Increase Reserved
1 2 Start Sequence (i/p 2) Volts (kVAr) Decrease Reserved
0 1 Enable Run (i/p 1) Volts (kVAr) Increase Reserved
It should be noted that the master module (GSM) data address points differ from the address points
of the CGC modules.
38
18.6 Generator Multiplier for kWatt, kVAr & Volt Table (address offset 0)
Bits Function
0 Group 1
1 Group 2
2 Request to Dead Bus
3 Confirm Will Not Dead Bus
4 Dead Bus Close Time Out
5 kVAr Lag Limited (reserved)
6 kVAr Lead Limited (reserved)
7 Spare for Gen
8 Not available = 0
9 Is Gen Module = 0
10 Not used = 0
11 Not used = 0
12 Not used = 0
13 kWatt Multiplier – bit 1
14 kWatt Multiplier – bit 2
15 Voltage Multiplier
Bit 13 Bit 14 Multiplier Range

The kWatt multiplier 0 0 / 10 0 to 999kWatt
The kWatt multiplier 1 0 x1 1,000 to 9,999kWatt
The kWatt multiplier 0 1 x 10 10MW to 99.99MWatt
The kWatt multiplier 1 1 x 100 100MW to 600MW
This applies to ALL kWatt variables.
Bit 15 Multiplier Range

The Volt multiplier 0 x1 0 to 21.999kV
The Volt multiplier 1 x1 22 to 220 kV
This applies to ALL Voltage variables.
18.7 Process Limit Table
Address
Bit Bit Value Process Limit
15 32768 Reserved
14 16384 Reserved
13 8192 Reserved
12 4096 Reserved
11 2048 Reserved
10 1024 Reserved
9 512 Max. Process Integral
8 256 Min. Process Integral
7 128 Min. kWatt Limited
6 64 Reserved
5 32 Max. kWatt for Process
4 16 Min. kWatt for Process
3 8 Reserved
2 4 Process Input Loss
1 2 Process Setpoint Above Max.
0 1 Process Setpoint Below Min.
39
18.8 Communications Analysis Addressing
RS232 Comms Menu Item 032
i) Receive Fast Protocol Checksum OK Count Modbus Address 5906

ii) Receive Fast Protocol Error Count Modbus Address 5907
iii) Receive Normal Checksum OK Count Modbus Address 5908
iv) Receive Normal Error Count Modbus Address 5909
Si-TEC LAN Comms Menu Item 033
Error Count Checksum Displayed on Line 3

IRQ Error Count Displayed on Line 4
i) Receive Packet OK Count Modbus Address 5913

ii) Receive Error Count Checksum Modbus Address 5914
iii) Receive IRQ Error Count Modbus Address 5915
User RS485 Comms Menu Item 034
Error Count Checksum Displayed on Line 3

Length Error Count Displayed on Line 4
i) Receive Packet OK Count Modbus Address 5910

ii) Receive Error Count Checksum Modbus Address 5911
iii) Receive Length Error Count Modbus Address 5912
This menu Item display also shows on the bottom line: TXE = 0 (or 1) FL = 0 (or 1)
If the value is one in TXE this indicates that the transmission is active. This should mostly
display 0 and flash to 1 on a comms request. If fixed at a value of 1 the Xtend is locked in
transmit mode.
NOTE: The counters are reset by powering down & re-booting of the module, or by
pressing the RESET key when in the menu after having Technical Access.
Modbus Address Values
Menu Item 087 provides for selecting a Modbus address number (3rd line at right side).
The value of the Modbus address is displayed to the left of the 3rd line.
The left of the 4th line displays the next Modbus address number.
40
NOTES
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41
NOTES
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42
Appendix
Si-TEC Xtend
Control
Specifications and
Illustrations
43
Si-TEC Xtend CGC Control Specifications
Power Supply
Nominal Voltage 24 Vdc (reverse polarity protected)
Operating Range 20 to 32 Vdc
Power Consumption up to 25 W + actuator load
Inrush Current 2 Amps for 0.1 ms
Speed Signal Inputs (2)

Speed Input Voltage (AC r.m.s.) 0.8 to 80 Vac
Speed Input Frequency Magnetic Pickup: 200 Hz to 20 kHz
Proximity Switch: 200 Hz to 20 kHz
Internal impedance per channel 10 kOhms
Voltage Sensing Inputs

Max.Voltage Range (AC r.m.s.) 10 Vac to 600 Vac (ph-ph) or 6 Vac to 346 Vac (ph-n)
Phases 3
Frequency Range 45 to 66 Hz (nominal)
V.T. Burden less than 0.1 VA per phase
Current Sensing Inputs

Current Range (AC r.m.s.) 0 to 1 Amps or 0 to 5 Amps (nominal)
Phases 3
Frequency Range 45 to 66 Hz (nominal)
C.T. Burden less than 0.1 VA per phase
Logic Inputs (16)

Voltage 9 to 36 Vdc
Max.Voltage short term 110 Vdc for 1 second
Relay Outputs (9)

Relay 1 to 4 N/O contacts, 2A @ 240 Vac or 30 Vdc for resistive load
Relays 5 to 8 Change-Over contacts, 5A @ 240 Vac (limited to 1000 VA)

or 125 Vdc or 30 Vdc when UL/CSA standard is applied
(limited to 150W) for resistive load
Analog Inputs (4)

Analog Input 1 & 2 4-20 mA into 62 Ohms
Analog Input 3 4-20 mA into 240 Ohms or 0-5 V into 100 kOhms
Analog Input 4 RTD: 2 wire – PT100 sensor
Analog Outputs (3)

Analog Outputs 1, 2 & 3 4-20 mA (burden range of 50 to 600 Ohms per channel)
RS232 Communication - Diagnostics Port

Protocol Modbus ASCII (up to 19200 Baud Rate)
Pin Connection pin 2 receive, pin 3 transmit and pin 5 ground
Isolation pin 5 referenced to ground
RS485 Communication – Si-TEC LAN

Protocol Si-TEC proprietary
Maximum Cable Loop Length 1200 metres using Dawson Technology network cable
RS485 Communication – Customer (User) LAN

Protocol Modbus ASCII or Modbus RTU (up to 19200 Baud Rate)
Maximum Cable Loop Length 1200 metres using Dawson Technology network cable
44
CAN Bus Communication
Protocol Si-TEC proprietary
Maximum Cable Loop Length 125 metres (250 kbps) with Dawson Technology network cable
Dimensions and Weight

Width 414 mm
Height 315 mm
Depth 88 mm
Weight 6.2 kg
Environment
Operating Temperature -10 to +60ºC (+14 to +140ºF)
Storage Temperature -20 to +70°C (+4 to +158°F)
Humidity 95% at +20ºC to +55ºC (+68 to +131ºF) non-condensing
45
Si-TEC Xtend
Control
Illustrations
46
Si-TEC Xtend Interfaces
To
Other
Generators
Actuator
Flywheel
Gen
Breaker
GEN Turbine
AVR MPU
Plant Load
(2)
AVR Speed Act. Act. Fuel

Bias Sensors Output Feedback Solenoid
Gen CT(3φ) Barring

Si-TEC
Si-TEC
Lubricate
Gen PT(3φ)
User PSMS
Bus PT(3 φ) RS-485
Mains
Breaker
Gen CB Aux Xtend Si-TEC
RS-485
To other Si-TEC
Close / Trip Gen CB Xtend modules
Mains CB Aux CGC CAN BUS

Alarm (Trip)
kW Ref. Control
Alarm (Status)
4-20 mA
OPAL
Logic Inputs Analog Outputs
Monitor
kW Ref. Operator Control Switches Analog Display

Supply Grid Alarms
Control Panel
Si-TEC Xtend CGC Application Wiring Diagram
LAN B
To Other LAN A To Other

Si-TEC Si-TEC
Xtend Common Xtend
Modules Modules
Shield
kW kVAr PF
N
SUPPLY
AUTHORITY C
-A
INCOMING
B
MAINS -E
StG TURBINE GOVERNOR ACTUATOR
Heinzmann StG 6 to StG 90
A -D 6-01 (other manufacturer's actuators optional)
Yellow
Blue
Red
Bus PTs To -C
Mains Expansion
CB I/O Modules
2 Amp
-B
(or Opal)
            | | | | | | | | | | | | | | | | | | | | | | |
48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
36 37 38 39 40 41 42 43 44 45 46 47 Output
Gnd S Com. A B Gnd S Com. L H S Sig. 0V (+) S + - S + - S + - 71-
S - + S - + S - + S - +
- 100 A φ AO - 1 AO - 2 AO - 3 Return
AI - 1 AI - 2 AI - 3 AI - 4
Si-TEC LAN CAN BUS Feedback AVR 72-
Analog Inputs (H-Drive Analog Outputs Bias
Isolator - 101 B φ
Bus Actuator 73-
- 102 Cφ Volts only)
Gen. CB
75-
CB Relay - 103 N
Actuator Black
Gen PTs 2 Amp Output
76-
- 104 Aφ
Red
77-
- 105 Bφ
Generator
Volts
79- Magnetic
Pickup
- 106 Cφ Speed
- 107 N
Si-TEC Xtend CGC Sense 1
80-
82-
Other CT Loads (Co-Generation Control) 200 Hz to 20,000 Hz
S1 - 108 ¬ 84- (Min. to Max. range)
Aφ Speed Optional
P1 S2 - 109 ↵ 85-
Generator Sense 2
S1 87-
- 110 ¬ Current
Generator CTs Bφ
Transformer
P1 S2
- 111 ↵
88- To PLC /
Inputs RS 485
S1 - 112
to SCADA
¬ User 92-
Cφ System
P1 S2 Lan
- 113 ↵
Logic Inputs 10 Amp
- 114 ¬
Use 1 Amp or 5 Amp Relay Outputs + 93-
Enable Run
Common(-)
neutral
Start Seq.
Secondary CTs Power

Gen CB
(optional)
- 115 ↵
Close
CB
R1 R2 R3 R4 R5 R6 R7 R8
Supply
- 94- 2 Amp
NO C C NO NO NO NO NO C NC NO C NC NO C NC NO
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C NC
95- 24 VDC
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
| | | | | | | | | | | | | | | | | Supply
B C | | | | | | | | | | | | | | | | | | |
A N
Close For Rated
Generator User Selected User Selected

Enable Run
Start Seq.
Gen. CB
Mains CB
Reverse Power
Open Gen. CB
At Running
Alarm
AVR
Speed
Synchronising
Fuel Solenoid
Si-TEC Xtend Power Supply (nominal 24 Vdc) Connections
Actuator Actuator
Turbine (Heinzmann Turbine (Heinzmann
StG) StG)
Actuator cable W2 Actuator cable W2
Control Panel Control Panel
PLC PLC
and and
Discrete Battery Discrete Battery
I/O I/O
Power Supply
On/Off- 20 Amp
W1
93 10 Amp 94
Si-TEC Si-TEC 10 Amp
Xtend Charger Xtend Charger
94 93
Power Supply
On/Off- 20 Amp
W1
INCORRECT WIRING CORRECT WIRING

This is because the ripple voltage of the charger is (1) The typical current drawn by the Si-TEC Xtend
fed directly into the electronic governor ! This may Cable size should not be less than: module is < 0.8 Amp + actuator current.
cause damage to the actuator ! (2) It is advised that the battery charger should be
W1: 2 X 1.5mm² (upto 7m)
2 X 2.5mm² (7 to 12m) suited to operate as a power supply, and must not
2 X 4.0mm² (12 to 20m) produce voltage spikes in the event of the battery
W2: Output: 2 X 1.5mm² (up to 10m) leads being disconnected.
2 X 2.5mm² (10 to 20m)
Feedback: 3 X 0.75mm² (with shield)
Si-TEC Xtend - Actuator, MPU and AVR interface
Output
For Analog biasing only.
AVR
71
AVR 72 Return (contact AVR manufacturer for
Bias further interface details)
73
58
Feedback Yellow A
59
(H-Drive
Blue TURBINE GOVERNOR ACTUATOR
Si-TEC
E
Actuator 60
Heinzmann StG 6 to StG 90
only)
61
Red D
Actuator (other manufacturer's actuators optional)
Xtend Actuator
Output
75
76
Black C
Module 77
Red B
Red
79 A
Magnetic 200 Hz to 20,000 Hz
Black
Speed 80 B Pickup (Min. to Max. range)
Sense 1
82
84 Optional
Speed 85 MPU (for
Sense 2 redundancy)
87
Note:
(2) The Actuator Output, Actuator Feedback and
Magnetic Pickup (MPU) cable looms are all
supplied by Dawson Technology.
(2) The MPU used must be dedicated for the
Si-TEC Xtend control. Any further devices
requiring speed sensing (eg. Overspeed,
Tachometer, etc) must utilise a separate MPU.
Si-TEC Xtend Voltage and Current Sensing Inputs
Main Bus (Islanded or

Supply Grid)
N
To Other C To Other
Generators Generators
(or Supply B (or Supply
Grid) Grid)
A
Bus PTs
2 Amps
100 Aφ
101 Bφ
Bus
102 C φ Volts
Gen.
103 N
CB
Gen PTs 2 Amps
104 A φ
105 Bφ
106 C φ
Generator
Volts
Si-TEC
107 N Xtend
Control
Other CT Loads
S1 108 ¬
Aφ
S2 109 ↵
P1 Generator
S1 110 ¬ Current
Generator CTs Bφ
Transformer
S2 111 ↵
P1 Inputs
S1
112 ¬
Cφ
S2 113 ↵
P1
114 ¬
neutral
(optional)
115 ↵
Use 1 Amp or 5 Amp

Secondary CTs
B C
Note: A N
(1) The voltage range of Generator and Bus Volts PTs may be set to
63.5 Vac Ph/N or 240 Vac Ph/N. Refer to manual 549-019 (Chapter 3)
for further details.
(2) For a nominal voltage of 120 Vac Ph/N, the 240 Vac Ph/N range
should be selected.
Generator
(3) The CTs should be wired to the Si-TEC Xtend Control based on the
S1 and S2 notation (as illustrated), provided P1 of the CTs is facing
the generator.
(4) The burden required from the CTs is less than 0.1 VA.
Si-TEC Xtend Logic Input and Relay Output Wiring Terminals
Si-TEC Xtend 10 Amp
Control Power
93-
94-
- +
2 Amps
Supply
24 Vdc
95- Supply
Logic Inputs Relay Outputs

Close CB RL1 RL2 RL3 RL4 RL5 RL6 RL7 RL8
Enable Run
Common(-)
Mains CB
Start Seq
Gen CB
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
User User
Selected Selected
Selected
User
At "Running Speed"
Reverse Power Alarm

Input 1 : "Emergency Stop" Switch
Close Gen. CB
Open Gen. CB
Fuel Solenoid
Synchronising
Input 2 : "Start / Stop" Switch Notes:

Input 3 : Generator CB Aux. Contact (1) It is recommended that the logic input supply be obtained directly from the Si-TEC Xtend power
Input 4 : Mains CB Aux. (for CGC only) supply terminals. Refer to manual 549-018 (chapter 6) for hardware specification details.
Input 5 : "Rated Speed" (user selected) (2) Relays RL1 to RL4 are 'NO' contacts using a common supply. Relays RL5 to RL8 have change
over contacts and an isolated common. Refer to manual 549-018 (chapter 7) for the external
interposing relay specifications.
(3) Logic inputs 1 to 4 are fixed functions, while logic input 5 (illustrated here) is a user-select function
Typical User Selected Relay ("Rated Speed" select) used in most steam turbine applications.
Outputs (4) The relay output "Close CB" is a fixed output function, while relays RL1, RL2, RL4, RL5 and RL6
are selectable functions, as illustrated here.
Si-TEC Xtend Analog Input & Analog Output Wiring Terminals
Metering Panel
kWatts kVArs PF
(+) (-) (+) (-) (+) (-)
User Select
Analog Inputs
36 37 38 39 40 41 42 43 44 45 46 47 62 63 64 65 66 67 68 69 70
S (-) (+) S (-) (+) S (-) (+) S (-) (+) S (+) (-) S (+) (-) S (+) (-)
AI - 1 AI - 2 AI - 3 AI - 4 AO - 1 AO - 2 AO - 3
(4-20 mA) (4-20 mA) (4-20 mA) (RTD) (4-20 mA) (4-20 mA) (4-20 mA)
Analog Inputs Analog Outputs
Si-TEC
Xtend
Control
Note:
(1) Refer to manual 549-018 (chapter 8) for complete list of user select analog inputs, as well as
hardware specification.
(2) The analog outputs illustrated above are the factory default settings. Refer to manual 549-018
(chapter 9) for complete list of analog output options, and hardware specification.
(3) The analog 4-20 mA outputs (current sink) are referenced from the 24 Vdc positive supply. If the
driven device (eg. PLC, DCS, etc.) is referenced to a negative supply, a line isolator will be required.
(4) It is essential to adopt standard instrumentation practices with regards to cabling, noise
interference and isolation.
Si-TEC Xtend LAN Terminations
Si-TEC Si-TEC Si-TEC Si-TEC

Xtend Xtend Xtend Xtend
Module 1 Module 2 Module 3 Module 4
(upto 24)
Common
Common
Common
Common
Ground
Ground
Ground
Ground
LAN A
LAN B
LAN A
LAN B
LAN A
LAN B
LAN A
LAN B
Shield
Shield
Shield
Shield
48 49 50 51 52 48 49 50 51 52 48 49 50 51 52 48 49 50 51 52
Si-TEC Si-TEC
Terminator Terminator
Note :
(1) The cable requirement is Dawson Technology RS485 LAN (part no. 660-040).
(2) Terminator (part no. 444-303) to be at the end of each loop (between A and B).
(3) The cable must loop directly from module terminals, with no "TEE OFFS".
(4) The shield should be grounded at one point only (terminal 48).
(5) The maximum total loop length for the "Si-TEC LAN" network is 1200 metres.
(6) The "Si-TEC LAN" network allows communication for up to a maximum of 24 Si-TEC
Xtend modules
Magnetic Pickup Mounting Details
Tooth Profile
Any tooth profile is admissible. The top width of the tooth should be 4 mm minimum, the gap
and the depth of the gap at least 6 mm. For index plates the same dimensions are valid.
For proper speed sensing, the magnetic pickup(s) MUST be mounted RADIALLY to the ring gear.
(see below)
Clearance of Magnetic Pickup
The distance between the magnetic pickup(s) and the tooth top should range from 0.5 to 1.0 mm.
It is possible to screw in the magnetic pickup till it touches the tooth (with engine / turbine stationary)
and then unscrew it for about half turn.
Gap >= 6 mm (at least)
Top Width >= 4 mm (at least)
Depth >= 6 mm (at least)
Standard MPU size is 5/8"-18UNF

(thread lengths at 63mm, 76mm or 101mm)
Optimum Air Gap : 0.5 - 1.0 mm
Clearance of Pickup
Dawson Technology
Technical Data: StG16-01 StG30-01 StG40-10
Output Shaft Travel 42° 42° 42°
Maximum Torque – Peak 15 Nm 28 Nm 44 Nm
Maximum Torque – Current Limit 7.5 Nm 14 Nm 22 Nm
Response Time (No Load 0 – 100%) 120 ms 170 ms 190 ms
Supply Voltage 24V DC 24V DC 24V DC
Max Supply Current – Steady State * 2.0 A 2.0 A 2.5 A
Max Supply Current – Continuous * 3.0 A 3.0 A 3.5 A
Max Supply Current – Peak * 5.0 A 5.0 A 6.0 A
Operating Temperature –25 to 90 °C –25 to 90 °C –25 to 90 °C
Storage Temperature –55 to 110 °C –55 to 110 °C –55 to 110 °C
Humidity Up to 100% Up to 100% Up to 100%
Protection Grade IP55 IP55 IP55
* Max current values (above) include 1.0 A current required by Si-TEC Xtend control module.
NOTE: StG16-90, StG30-90 and StG40-90 actuators are similar to StG16-01, StG30-01 and
StG40-10 actuators respectively, except for 90 degree travel to provide greater work output.
Dawson Technology
Dimensions of StG 16-01, StG 30-01 and StG 40-10 actuators (mm)
216 180
30 81
38
Max
100
Mid
42°
50
Mii n
SAE Serration 1/2" - 36
0
HEINZMANN
Serial No.
R
GmbH + C o.
Am Haselbach 1
D-79677 SchÎnau for BasicSystem E
Ger many
Telefon: ( 07673) 8208- 0
Telefax: (07673) 8208-88
Range Voltage
Patents pending
66
289
M8
238
Diese Schraube darf nicht verstellt werden!

Never turn this screw!
Ne pas toucher a cette vis!
A B
74
72
18 12
2
11 70 72
79,5
151,5
180
81
section A-B
38
Max
100
42°
50
Mid Min
0
125,4
146
HEINZMANN
Serial No.
R
GmbH + C o.
217
Am Haselbach 1
D-79677 SchÎnau for BasicSystem E
Germany
Telefon: ( 07673) 8208-0
Telefax: (07673) 8208-88
Range Voltage
Patents pending
166
112,7 Diese Schraube darf nicht verstellt werden!

Never turn this screw!
Ne pas toucher a cette vis!
134
Bottom view of mounting adaptor and dimensions of actuator without adaptor

The power source of the all-electric StG actuator is a DC disc motor whose torque is transmitted
to the output shaft via a gearbox.
To increase the lifetime of these actuators and eliminate the need for maintenance, specially
developed materials and heavy lubricants are used throughout.
Further, the output shaft is fitted with a feedback excenter, which allows a sensor to read the
position of the shaft without actually touching it. The sensor then transmits this information to the
control unit.
Technical Data: StG6-01 StG6-02 StG10-01

Output Shaft Travel 36° 36° 36°
Maximum Torque – Peak 4 Nm 6 Nm 10 Nm
Maximum Torque – Current Limit 2 Nm 3 Nm 5 Nm
Response Time (No Load 0 – 100%) 70 ms 75 ms 80 ms
Supply Voltage 24V DC 24V DC 24V DC
Max Supply Current – Steady State * 2.0 A 2.0 A 2.0 A
Max Supply Current – Continuous * 3.0 A 3.0 A 3.0 A
Max Supply Current – Peak * 5.0 A 5.0 A 5.0 A
Operating Temperature –25 to 90 °C –25 to 90 °C –25 to 90 °C
Storage Temperature –55 to 110 °C –55 to 110 °C –55 to 110 °C
Humidity Up to 100% Up to 100% Up to 100%
Protection Grade IP44 IP44 IP44
Dawson Technology
Dimensions of StG6-01 & StG6-02V actuators (mm)
125
94
36°
83
23
182,5
100 0
173 50
Maximum Mid Minimum
151
133
5,5
X 123
7
100
80
75
95
110
Bottom view of StG6-01 & StG6-02V actuators

Dawson Technology
Dimensions of StG10-01 actuator (mm)

125
94 36°
83
23
100 0
50
Maximum Mid Minimum
202
193
173
155
5,5
X 143
7
100
80
75
95
110
Bottom view of StG10-01 actuator

Technical Data: StG64-01 StG90-01
Output Shaft Travel 42° 42°
Maximum Torque – Peak 64 Nm 90 Nm
Maximum Torque – Current Limit 32 Nm 45 Nm
Response Time (No Load 0 – 100%) 250 ms 310 ms
Supply Voltage 24V DC 24V DC
Max Supply Current – Steady State * 2.5 A 2.5 A
Max Supply Current – Continuous * 3.0 A 3.0 A
Max Supply Current – Peak * 8.0 A 8.0 A
Operating Temperature –25 to 90 °C –25 to 90 °C
Storage Temperature –55 to 110 °C –55 to 110 °C
Humidity Up to 100% Up to 100%
Protection Grade IP55 IP55
Dawson Technology
(in mm)
Appendix:
Split Shaft Turbine
Alternator Application
For “Split Shaft” steam turbine alternator applications (eg. Stal – Laval
steam turbine alternators), the following functionality of the Si-TEC Xtend
CGC and Opal Generator Annunciator should be noted:
1) The speed sensing for “Split Shaft” steam turbine alternator

application would be based on the Si-TEC Xtend CGC governor
module sensing a MPU from one alternator and the Opal Generator
Annunciator module sensing a MPU from the other alternator.
2) The Si-TEC Xtend CGC module reads the MPU sensing speed of the
Opal Annunciator module via the “High Speed” CAN Bus port (at 250
kbps), ensuring that accurate speed measurements of both alternator
shafts are continuously measured and monitored.
3) The Si-TEC Xtend CGC module “Split Shaft” sensing mode is

automatically enabled (armed) when turbine speeds of both alternators
measured is above 500 RPM.
4) The Si-TEC Xtend CGC module will detect a “Turbine Speed

Mismatch” when the speed deviation between both alternator shaft
speeds exceeds 290 RPM. Beyond this, the Si-TEC Xtend CGC will
immediately shut down the turbine.
5) Should there be a “Communication Loss” in the CAN Bus between the

Si-TEC Xtend CGC module and Opal Generator Annunicator module,
the Si-TEC Xtend CGC will detect a “Turbine Speed Mismatch” due
to loss of CAN Bus communication and will immediately shut down the
turbine.
6) The Opal Generator Annunicator “Overspeed Protection” function

will continue to function independent of the Si-TEC Xtend CGC
governor module.

CGC-MF Split Shaft Steam Turbine - DesignInstallation - Rev H

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CGC-MF Split Shaft Steam Turbine - DesignInstallation - Rev H

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Si-TEC Xtend series 2

CGC (Co-Generation Control)

Design and Installation Manual

Manual No. 549-022 rev H

Dawson Technology Pty Limited

2 Features Si-TEC Xtend CGC……………………………………………………………….. 3

4 Input / Output Description Introduction…………………………………………………… 7

10 Analog AVR Bias Output…………………………………………………………………... 24

11 Turbine Governor Connections…………………………………………………………… 25

12 Voltage and Current Sensing…………………………………………………………….. 26

14 RS485 and RS232 Communications……………………………………………………. 28

18 Si-TEC Xtend Communications Addresses accessed from RS232 Communications

Appendix – Si-TEC Xtend Control Technical Details and Illustrations………………… 43

Co-Generation Control (CGC)

The Si-TEC Xtend Co-Generation Control (CGC) is a 32–Bit microprocessor-based turbine-generator

1. Isolated prime power stations.

kWatt Limiting of individual turbine-generators, using 4-20mA inputs.

The relay output control functions include:

The relay output alarm functions include:

The menu driven readout displays full system information including:

System Designers should made special note of items marked "##"

The following is a description of terms used within this document:

Analog Input: RTD, 0-5V, or 4-20mA input signals.

Analog Output: 4-20mA output for driving external metering etc.

Logic Input: a switched input voltage (nominally 24Vdc).

Relay Output: voltage free contacts for providing output control.

High Input: when 24Vdc is applied to a logic input.

Low Input: when the logic input has 0Vdc applied.

Generator CB: the respective generator circuit breaker.

SP: Set Point or Reference Value

PV: Process Variable or Measured Value

## THIS IS A CONTROL DEVICE AND IS NOT TO BE USED FOR TURBINE SPEED

6.1 Fixed Logic Inputs

Enable Run - Input 1 (terminal 1)

Start Sequence - Input 2 (terminal 2)

Upon input 2 going "High" (provided input 1 is "High"):

Upon input 2 going "Low" (removal of "Start Seq." signal):

Generator CB Closed - Input 3 (terminal 3)

Mains CB Closed - Input 4 (terminal 4)

6.2 User Select Logic Inputs

Logic Input Terminals 5 to 16 (total of 12 user select inputs)

Enable Input Control via Modbus

Enable Input Control via Modbus

Remote Fault Reset

Over Speed Test Select

Enable Load Share Select

Base Load (1 and 2)

Gen Group 1 to 4 – (1st Bit and 2nd Bit)

Main Bus - Re-Sync to Grid

Enable Minimum Import Select

Manual Speed Increase

Manual Voltage Increase

Manual Voltage Decrease

“Auto” Input menu 438

“Auto” Input – “Low” (Manual Mode)

“Auto” Input – “High” (Automatic Mode)

(1) “Warm Up at Rated RPM Hot”

Permissive Sync. Mode Select

Dead Bus Enable Select

Enable Process Control Select

Process Ref. Analog Select

Process Increase Select

Process Decrease Select