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ControlReg200/ControlReg200P
Electric Power Generation Installation and maintenance 5304 en - 2016.05 / c
This manual concerns the ControlReg series which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual. By following
certain important points during installation, use and servicing of your product, you can
expect many years of trouble-free operation.
Before using your ControlReg for the first
time, it is important to read the whole of this
installation and maintenance manual. Warning symbol for electrical danger to
All necessary operations and interventions
on this machine must be performed by a
Our technical support service will be pleased
to provide any additional information you
The various operations described in this All such operations performed on the
manual are accompanied by recom- ControlReg should be undertaken by
mendations or symbols to alert the user to personnel trained in the commissioning,
po­tential risks of accidents. It is vital that you servicing and maintenance of electrical
understand and take notice of the following and mechanical components.
This ControlReg can be incorporated in
a machine marked C.E.
© - We reserve the right to modify the
WARNING characteristics of its products at any time in
order to incorporate the latest technological
Warning symbol for an operation developments. The information contained in
capable of damaging or destroying the this document may therefore be changed
machine or surrounding equipment. without notice.
This document may not be reproduced in
any form without prior authorization.
All brands and models have been registered
and patents applied for.
Warning symbol for general danger to
1 - GENERAL INFORMATION.................................................................................................4
2 - GENERAL PRODUCT INFORMATION...............................................................................4
3 - PASSWORDS..................................................................................................................... 6
4 - FUNCTIONAL DESCRIPTIONS..........................................................................................8
5 - DISPLAY AND MENU STRUCTURE.................................................................................35
6 - ENGINE COMMUNICATION.............................................................................................35
7 - AVR (AUTOMATIC VOLTAGE REGULATOR) FUNCTIONS............................................35
8 - ADDITIONAL FUNCTIONS...............................................................................................42
9 - PROTECTIONS................................................................................................................. 80
10 - PARAMETERS LIST.......................................................................................................83
11 - MOUNTING..................................................................................................................... 83
Disposal and recycling instructions
1 - GENERAL INFORMATION 2 - GENERAL PRODUCT
1.1 - About the technical manual INFORMATION
1.1.1 - General purpose 2.1 - Introduction
This technical manual mainly includes This chapter will deal with LS ControlReg
functional descriptions, presentation of series which is a combined solution
display unit and menu structure, the integrating a genset controller and a
procedure for parameter setup and generator voltage regulator. It is a cost-
reference to parameter lists. effective and compact product.
The general purpose of this document is to
2.2 - Type of product
provide useful overall information about the
functionality of the controller and its The ControlReg is a micro-processor based
applications. This document also offers the control unit containing all necessary
user the information he needs in order to functions for protection and control of a
successfully set up the parameters needed genset.
in his specific application. It contains all necessary 3-phase measuring
circuits, and all values and alarms are
presented on the LCD display.
The ControlReg will come in two different
variants: ControlReg200 and
ControlReg200P.
Please make sure to read this document The ControlReg200 is the unit that is able to
before starting to work with the controller perform auto start, and the ControlReg200P
and the genset to be controlled. Failure is able to make the automatic mains failure
to do this could result in human injury or (AMF) sequences. The hardware for the two
damage to the equipment. products is different, therefore some of the
sequences described in this document are
1.1.2 - Intended users only relevant to one of the variants. You will
This Designer’s Reference Handbook is find a detailed description of the available
mainly intended for the panel builder functions in each product in the chapter
designer in charge. On the basis of this «Standard Functions».
document, the panel builder designer will For detailed specifications of the hardware,
give the electrician the information he needs please refer to the datasheet.
in order to install the unit, e.g. detailed
electrical drawings. In some cases, the 2.3 - PC utility software warning
electrician may use these installation
2.3.1 - PC USW warning
instructions himself.
1.1.3 - Contents and overall structure
This document is divided into chapters, and
in order to make the structure simple and
easy to use, each chapter will begin from the It is possible to remote-control the
top of a new page. genset from the PC utility software. To
avoid personal injury, make sure that it is
safe to remote-control the genset.
Trying to do this. The USB powered mode can be used for setting up the controller with the USW. settings 11150. 10800. 11020. 11000.3. The power gathered by the USB is not enough for the complete unit to work properly and the AC measurements will not be accurate. Name Menus AVR settings 2500 and 2600 AC configuration 9130 Multi input 10460. 11010.3 . LEROY-SOMER do not recommend to For the USW. when USB is the only source of power. This indicates that all the AC measurements.Parameter change while engine running Due to the critical behavior that can be seen if some of the parameters are changed while engine is running. 11080.3. The writing of the parameter is therefore not taken into consideration. 11030. only the communication to the PC tool «USW» will be possible. 11320. Electric Power Generation Installation and maintenance 5304 en . 11300. are not 2. See below picture: It is possible to power the ControlReg200 only with the USB-cable. Parameters which cannot be changed while the engine is running are the AVR settings (except voltage level).05 / c ControlReg200/ControlReg200P The unit will display a view automatically which says «USB powered.USB powered mode reliable. corner. it is not authorized to change the following parameters unless the engine is stopped. 11310. However. 11350 5 . 11330. perform a batch-load. 10630. 10990. seen on the USW. a banner saying «USB use the USB as the primary power supply powered» will appear in the lower right for the unit.2016. change the parameters and translations and configure Mlogic. AC configuration and multi input settings. 1 & 2. It will not be possible to operate the unit from the display.2 . limited functionality» and it will remain there as long as there is no proper power on term. 11160. It is possible to flash the controller with application software. both the display and the USW will pop-up a message indicating that the action is not allowed. 11340. Therefore the HW is not usable. 2. 10980. The affected parameters are located in the menus in below table.
2016.1.1 . the PC utility software must be used.PASSWORDS 3. Electric Power Generation Installation and maintenance 5304 en . Each parameter can be protected by a specific password level. Available password levels: Access Password level Factory setting Customer Service Master Customer 2000 X Service 2001 X X Master 2002 X X X A parameter cannot be entered with a password that is ranking too low. All levels can be adjusted in the PC software. But the settings can be displayed without password entry. Enter the parameter to be configured and select the correct password level.Password The unit includes three password levels.1 .Passwords and parameter access 3. To do so. 6 .05 / c ControlReg200/ControlReg200P 3 .
7 . It is not possible to change the password at a higher level than the password entered. Electric Power Generation Installation and maintenance 5304 en . The service password can be changed in jump menu 9117. it is not possible to enter the parameters.2 .2016. The factory passwords must be changed if the operator of the genset is not allowed to change the parameters. the password level must be entered: If the password level is not entered. 3.Parameter access To gain access to adjust the parameters.1. The master password can be changed in jump menu 9118. The customer password can be changed in jump menu 9116.05 / c ControlReg200/ControlReg200P The password level can also be changed from the parameter view in the column «Level».
1.Engine control 4.2 x under-voltage (27) .Voltage unbalance (60) .1. Flowcharts and single-line diagrams will be used in order to simplify the information.1.2 x under-frequency (81) .Digital inputs 4.2 . .2016. Pt100. Electric Power Generation Installation and maintenance 5304 en .3 . the ControlReg200 has a lighter specification than the ControlReg200P.2 x overvoltage (59) . The standard functions are listed in the following paragraphs.05 / c ControlReg200/ControlReg200P 4 . The table below describes which points differ from each other. depending on the variant of the ControlReg to be used.Load takeover . Pt1000 or RMI) .Standard functions This section includes functional descriptions of standard functions as well as illustrations of the relevant application types.2 x overload (32) The busbar protections are only available .2 x over-voltage (59) .Reverse power (32) .1.4 x overcurrent (50) for ControlReg200P.Generator protection (ANSI) .Multi-inputs .1 . 4-20 mA.Standard functions 4. Application Comment Automatic Mains Failure (AMF) (no back sync.Busbar protection (ANSI) .Island operation (digital. The table below describes the genset modes that are available.) ControlReg200P Island operation ControlReg200/ControlReg200P Load takeover ControlReg200P On the hardware point of view.2 x over-frequency (81) 4.Current/voltage unbalance (60) .2 x undervoltage (27) .FUNCTIONAL DESCRIPTIONS 4.1.Operation modes . Feature Available on Available on (terminal numbers) ControlReg200 ControlReg200P Mains measurement (term.1 .Start/stop sequences .Automatic Mains Failure .Loss of excitation / overexcitation (40/32RV) 8 .5 .Run and stop coil . 21 to 24) No Yes 4.4 .2 x over-/underfrequency (81) .
Push-button for switching between MAN/AUTO .1. Electric Power Generation Installation and maintenance 5304 en .1.Event and alarm logs The controller is saving information about the latest events and alarms.Push-buttons for start and stop .Push-button for Mute/Access to Alarms and Events .Display . both are containing up to 50 logs each. 4.Push-buttons for navigating the menus . The date and time has to be updated for correct time stamp on the logs.M-Logic .7 .8 .Simple logic configuration tool .1.Status texts .Selectable input events .Push-buttons for breaker operations .05 / c ControlReg200/ControlReg200P 4.2016.6 .Selectable output commands 9 . The information is gathered in the «Event log» or the «Alarm log».Push-button for viewing alarms and silencing alarm horn 4.
Configure the ControlReg to match the correct measuring system. voltage Phase-neutral voltage of the generator 230V AC Primary voltage of the G voltage transformer 6041 G transformer UNOM x √3 (if installed) Secondary voltage of the G voltage 6042 G transformer UNOM x √3 transformer (if installed) Primary voltage of the BB voltage transformer 6051 BB transformer UNOM x √3 (if installed) Secondary voltage of the BB voltage 6052 BB transformer UNOM x √3 transformer (if installed) 6053 BB nom. contact the switchboard manufacturer for information about the required adjustment. The ControlReg200P has two sets of BB transformer settings. the three-phase system is selected.2 . When this principle is used.Three-phase system When the ControlReg is delivered from the factory. the measurement principle can be changed between three-phase and single phase.Single phase system The single phase system consists of one phase and the neutral.05 / c ControlReg200/ControlReg200P 4.2. Electric Power Generation Installation and maintenance 5304 en . which can be enabled individually in this measurement system. 10 . The following adjustments must be made to make the system ready for the single phase measuring (example 230V AC): Setting Adjustment Description Adjust to value 6004 G nom. voltage Phase-phase voltage of the busbar UNOM x √3 The voltage alarms refer to UNOM (230V AC).2 .2016.2. 4.Measurement systems In menu 9130. all three phases must be connected to the controller.1 . When in doubt. 4.
Electric Power Generation Installation and maintenance 5304 en . The unit can be used for the applications listed in the table below. 4.1 . 11 . It is not suitable for reading from beginning to end.3. voltage Phase-neutral voltage of the generator 400V AC Primary voltage of the G voltage transformer 6041 G transformer UNOM (if installed) Secondary voltage of the G voltage 6042 G transformer UNOM transformer (if installed) Primary voltage of the BB voltage transformer 6051 BB transformer UNOM (if installed) Secondary voltage of the BB voltage 6052 BB transformer UNOM transformer (if installed) 6053 BB nom.05 / c ControlReg200/ControlReg200P The following adjustments must be made to make the system ready for the three-phase measuring (example 400/230V AC): Setting Adjustment Description Adjust to value 6004 G nom.Applications 4. which can be enabled individually in this measurement system.) X X X X Island operation X X X X Load takeover X X X X For a general description of the available running modes.2016.Applications and genset modes This section about applications is to be used for reference using the particular genset mode as starting point.) ControlReg200P Island operation ControlReg200/ControlReg200P Load takeover ControlReg200P Power management Not available Running mode Genset mode Auto Test Man Block Automatic Mains Failure (no back sync.3 . voltage Phase-phase voltage of the busbar UNOM The ControlReg200P has two sets of BB transformer settings. please refer to the chapter «Running mode description». Application Comment Automatic Mains Failure (no back sync.
If «active» is ticked. The mains breaker will be opened at Now the application can be designed using genset start-up. the section control panel. 4. The active choice we can make here is the name of the application. When using the ControlReg. only one application will be available. «Continuous NE» or «Compact».3.05 / c ControlReg200/ControlReg200P 4. the name is used when making batch-files.AMF (no back synchronisation) Auto mode description The unit automatically starts the genset and switches to generator supply at a mains failure after an adjustable delay time.3.2 . the plant type will be stuck to «Single DG». 12 . it is defined whether a generator and a mains are present.Application design The application is designed through the utility software. If a ControlReg is connected. This means no CAN communication can be established with other units (No power management). and the number and type of breakers. This application configuration setup is here to give the user the choice of which breaker type is in use. The possible choice of breakers are «pulse». Electric Power Generation Installation and maintenance 5304 en . It is possible to adjust the unit to change to genset operation in two different ways: 1.3 . Please select «Application configuration».2016. For each area. The product will be automatically selected if you are currently connected to the unit when doing this configuration. Select a new application and adjust the settings in this dialogue box. Using the ControlReg. it will not be possible to draw an application with a mains or a mains breaker (only possible with ControlReg200P).
If Hz/V OK. It will only are used by activating and deactivating a initiate sequences.3. time-dependent start/stop commands are to 4. The start and stop commands the case with the auto mode. if external signals are multi input set to «binary» or with the time. The mains breaker will remain closed until The purpose of the load takeover mode is to the genset is running.Island operation be used. running modes. please refer to the dependent start/stop commands. are used by activating and deactivating a For a general description of the available multi input set to «binary» or with the time- running modes. activated twice. When the stop command is The unit can be operated in manual mode given. and the genset voltage transfer the load imported from the mains to and frequency is OK. If the chapter «Running mode description». The start and stop commands «Mains OK delay» has expired.05 / c ControlReg200/ControlReg200P 2. The switching back to the genset will be stopped after a cooling- mains supply is done when the adjusted down period. The genset will be stopped. When the stop command is switch back to mains supply and cool down given. and and stop the genset. then the auto mode must also be Auto mode description used. the GB is ready to close.3. port. A multi input set to «binary» is used. 1. When the mains returns. please refer to the 3. and the mains breaker is closes the generator breaker at a digital open. If the An external signal may be given in three time-dependent start/stop commands are to ways: be used. the generator breaker is tripped. the stop sequence will continue to be active in cancelled if the the ‘"extended stop time" period. Close GB The unit will close the generator breaker if the mains breaker is open. Display push-buttons are used.1 . Electric Power Generation Installation and maintenance 5304 en .4 .4. Manual means that the unit will not the genset will be stopped after a cooling initiate any sequences automatically.4 . The genset is stopped with stop button is cooling down time. The unit automatically starts the genset and 4. dependent start/stop commands. For a general description of the available 2. the genset for operation on generator In both cases. the generator breaker will be supply.2016. Close MB The unit will close the mains breaker if the generator breaker is open. 13 . 4. Open GB The unit will open the generator breaker instantly. the auto mode must also be used. the unit will start command.5 . and (MAN). the generator breaker is tripped. closed when the generator voltage and The unit automatically starts the genset and frequency is OK. Open MB The unit opens the mains breaker instantly. After disappearance of the running The cooling down time is Stop signal. Modbus commands are given at service chapter «Running mode description». Manual mode does not influence voltage regulation in ControlReg products.Running mode description closes the generator breaker at a digital 4.Load takeover The following sequences can be activated in Auto mode description manual mode: Command Description Comment The start sequence is initiated and continues until the genset Start starts or the maximum number of start attempts has been reached.Manual mode start command. given. as is down period.
it is generator breaker is opened. The purpose of the block mode is to make sure that the genset does not start for instance during maintenance work. If block mode is selected If the timer in parameter 7041 is set to 0. and the generator of the genset and that the genset is ready is stopped after the cooling down time.. It is possible to open and close the generator breaker and the mains breaker Alarms are not influenced by block mode in manual mode.4 .Test mode It is important to know that the binary The test mode function is activated by input configured to block mode is a activating a multi input set to «binary». locked for certain actions. when it is ON.4. shut down the engine.0 using the digital input. If block mode has been the input or changing mode to either activated in both ways. USB. selection. «BLOCK» in the display and flash the 7040 Test AUTO-LED. The unit is in a blocked state.Test The test will start the genset. if present.2 . and constant signal. So. the test sequence will be infinite. MB ON. from the display. it returns to the mode it was in the USW. the assigned to TEST mode functionality. When block The genset will shut down if block mode mode is selected. when connected to the unit over before block mode was selected.3 . When the test timer expires or the test is cancelled by mode change. 14 . Engine . Electric Power Generation Installation and maintenance 5304 en . show in menu 7040.open GB.05 / c ControlReg200/ControlReg200P 4. and when it is TEST mode can also be activated by use of OFF. the controller will be is selected while the genset is running. if present. .Return: When the test is completed.GB ON. START buttons are locked. it has to be manual or auto. When controller goes into block mode. 4. This means that it cannot start the genset or perform any breaker operations from the buttons. it will: The settings for the test function are set up .2016. the If block mode is selected using the display. GB OFF. the Before the running mode is changed. only be deactivated by setting the digital The test will be canceled by deactivating input to OFF. 4. unit will return to the selected mode (manual the block mode can only be deactivated or auto).4.Block mode Block mode can be enabled by pressing the STOP-button together with the AUTO- button for more than 1 second. for operation. the block mode can min. the mains important to check that persons are clear breaker closed. and close the generator breaker. open the mains breaker. alternatively with M-Logic or a binary input.Timer: Period starts when U/f is ok. MB OFF and stops when time runs out.4. deactivated with both ways of doing it. .
the principles of the most important functions will be illustrated in the 4.4 .Automatic Mains Failure 4.Single-line diagrams 4.05 / c ControlReg200/ControlReg200P 4.Stop sequence Controller .2016. the various applications are illustrated in single-line diagrams.Test sequence The flowcharts on the following pages are for guidance only.Automatic Mains Failure Load Controller Load Controller 4.Application illustration In the following.5.5 . Electric Power Generation Installation and maintenance 5304 en .Island operation next sections. For illustrative purposes.GB close sequence .1 . the flowcharts are simplified in some extent.MB open sequence .2 .3 .Start sequence .Mode shift .6 .Load takeover .MB close sequence .Flowcharts Using flowcharts.5.GB open sequence . 4. The functions included are: Load .1 .Flowcharts 4.5.Automatic Mains Failure .Island operation . 15 .5.6.
2016.Mode shift Start Mode shift No enabled Yes Plant mode not No Island and AMF Yes No Mains failure Yes Initiate AMF sequence No Yes Mains OK timer Initiate mains MB close Continue in timed out return sequence sequence selected mode End Mode shift is enabled in ch.05 / c ControlReg200/ControlReg200P 4.6. 16 . Electric Power Generation Installation and maintenance 5304 en .2 . 7081.
3 .MB open sequence 4.2016.6.4 .GB open sequence Start Start No No MB closed Stop conditions OK Yes Yes No Load take over Mains failure Is GB No closed Yes Yes Open MB Open GB No Alarm “MB No MB opened GB opened Alarm open failure” Yes Yes End End 17 . Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 4.6.
Stop sequence Start No Stop conditions OK Yes GB open No seq OK Yes AUTO No mode Yes No Cooldown timer run out Yes No Run coil Stop relay Yes Deactivate Activate stop run coil relay Genset No Alarm stopped Yes End 18 .5 .6. Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 4.2016.
6.2016.05 / c ControlReg200/ControlReg200P 4. Electric Power Generation Installation and maintenance 5304 en .6 .Start sequence Start No Start condition OK Yes No Start prepare timer Yes Start relay ON No No Start relay timer Genset started timeout Yes Yes Off relay Run feedback No Alarm ON detected Yes No No Stop relay timer U/F OK timeout Yes Yes No Max start Ready to attempts close GB Yes Start failure End alarm 19 .
2016. Electric Power Generation Installation and maintenance 5304 en .6.05 / c ControlReg200/ControlReg200P 4.7 .MB close sequence Start No MB open Yes No GB open No GB open GB open sequence failure Yes Yes Mains No Mains OK failure Yes No MB close Close MB failure Yes End 20 .
6.8 .2016. Electric Power Generation Installation and maintenance 5304 en .GB close sequence Start No GB open Yes No Start seq OK Yes No Volt/ freq OK Yes No MB open No MB open MB open sequence failure Yes Yes Mains No Mains OK failure Yes No GB close Close GB failure Yes End 21 .05 / c ControlReg200/ControlReg200P 4.
05 / c ControlReg200/ControlReg200P 4.2016. Electric Power Generation Installation and maintenance 5304 en .6.9 .Load takeover Start Activate start input Start sequence MB open sequence Genset operation GB close sequence Deactivate start input GB open MB close Stop sequence sequence sequence End 22 .
2016.10 .05 / c ControlReg200/ControlReg200P 4. Electric Power Generation Installation and maintenance 5304 en .Island operation Start Start input active Start sequence GB close Operation sequence Start input deactivated GB open sequence Stop sequence End 23 .6.
6. AMF Start No Mains failure Yes #7065: start No eng + open MB Yes Open MB Start sequence Start sequence Open MB GB close GB close sequence sequence No Mains OK Yes MB close End Time out sequence 24 . Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 4.Automatic Mains Failure.2016.11 .
menu 7043 End 25 .6. Electric Power Generation Installation and maintenance 5304 en .12 .Test sequence Start Select test mode Full test Start sequence Open MB Close GB Test timer sequence sequence Timer run out Yes Stop sequence Return to running mode.2016.05 / c ControlReg200/ControlReg200P 4.
7 .Sequences 4.2016.Breaker sequences 4. Stop coil Running feedback 1st start attempt 2nd start attempt 3rd start attempt 26 .START sequence .7. The following sequences will be illustrated below: . the generator breaker.7.1 . the run coil is activated before the start output (starter).Sequences The following contains information about the sequences of the engine. In the manual mode.2 . The time between the run coil and the start output is setup in parameter 6151. Electric Power Generation Installation and maintenance 5304 en . No matter the choice of start prepare function. but not close the breaker). and the mains breaker. In the following drawings this time is set to 1 sec. Start sequence: Normal start prepare Start prepare tOFF tOFF Crank (starter) Run coil 1 sec. These sequences are automatically initiated if the auto mode is selected.STOP sequence .05 / c ControlReg200/ControlReg200P 4. the selected sequence is the only sequence initiated (e.Start sequence The following drawings illustrate the start sequences of the genset with normal start prepare and extended start prepare.g. press the START push-button: the engine will start.
05 / c ControlReg200/ControlReg200P Start sequence: Extended start prepare Start prepare tOFF tOFF Crank (starter) Run coil 1 sec.1 . The rule is that the value (mA. the treshold value in channel 6186 must be between 0.2016.3 . then the crank output will not engage the starter motor.PT100/PT1000 . 27 .Start sequence conditions The start sequence initiation can be controlled by the following conditions (Multi inputs): . Electric Power Generation Installation and maintenance 5304 en .Binary This means that if e. the start sequence is initiated as soon as it is requested.9.0.RMI fuel level . If the value in 6186 is set to 0.4-20mA . Stop coil Running feedback 1st start attempt 2nd start attempt 3rd start attempt 4. the oil pressure is not primed to the sufficient value. fuel level or binary input) must exceed the setpoint of setting 6186 before starting is initiated.7. temperature. oil pressure.RMI water temperature .RMI oil pressure . The selection is made in setting 6185.g.0. If binary signal is used.
05 / c ControlReg200/ControlReg200P The diagram below shows an example where the RMI signal builds up slowly. no matter if the genset is started based on the primary or secondary feedback. The running detection is made with a built-in safety routine. Start sequence: Cranking depends on RMI Start prepare 1 2 2 (3 start attempts) Stop relay Crank relay Run coil Running feedback RMI measurement OK RMI value Cranking starts 4.Running feedback Different types of running feedback can be used to detect if the motor is running. 28 . all the types of running feedback is used for running detection. the genset will start.4 . This way. At all times. Refer to menu 6170 for selection of the running feedback type.7. the running detection will be made. and starting is initiated at the end of the third start attempt.2016. Electric Power Generation Installation and maintenance 5304 en . The running feedback selected is the primary feedback. based on all available types. the genset will still be functional even though a tacho sensor is damaged or dirty. As soon as the genset is running. If a running feedback is detected based on one of the secondary choices.
Start relay (crank) tAlarm Alarm Interruption of start sequence The start sequence is interrupted in the following situations: Event Comment Stop signal Start failure Remove starter RPM setpoint (based on MPU or frequency reading) feedback Running feedback Multi input set to binary Running feedback RPM setpoint (based on MPU or frequency reading). Running feedback failure Primary running feedback Secondary running feedback 1 sec.2016. 29 . If ch. 6171 (Number of teeth) is set to 0.05 / c ControlReg200/ControlReg200P The sequence is shown in the diagram below. Running feedback Oil pressure setpoint (menu 6175) Running feedback EIC (engine communication) Emergency stop Alarm Alarms with shutdown" or "trip and stop" fail class Stop push-button on Manual mode display Modbus stop Manual mode command Binary stop input Manual mode Deactivate the "auto Auto mode in the following genset modes: island operation or load start/stop" takeover mode. The controller cannot be equipped with both «CAN EIC» and «MPU» as they use the same terminals (term. binary input or engine communication. The frequency measurement requires a voltage measurement of 30% of UNOM. Electric Power Generation Installation and maintenance 5304 en . 1-3). 6176). Running feedback Frequency measurement above threshold (16-70Hz) (ch. the rpm is based on frequency measurement. The running detection based on the frequency measurement can replace the running feedback based on MPU.
g. Stop sequence: Run coil tCOOL Cooling down time Run coil tstop Running feedback Sequence initiated 30 . prepare time exceeds the start ON time. If the .Start failure alarm (4570 Start failure) Start ON time: the starter will be activated for The start failure alarm occurs.g. e.Start prepare (6180 Starter) . e. the start prepare function is (secondary). is not reached before the delay has expired. If the frequency and voltage are not within the start prepare output is deactivated when the limits set in menu 2110 after the running the start output deactivates. the extended prepare function is when the delay has expired. . this alarm will be raised. has not started after the number of start Start OFF time: the pause between two start attempts set in menu 6190.2016. The delay Extended prepare: the extended prepare to be set is the time from the secondary will activate the start prepare output when running detection and until the alarm is the start sequence is initiated and keep it raised. but the primary running deactivated. 4. if the genset this period when cranking.Crank failure alarm (4530 Crank failure) Normal prepare: the start prepare timer can This alarm will be raised if the specified RPM be used for start preparation purposes.05 / c ControlReg200/ControlReg200P Setpoints related to the start sequence .7. digital input.Hz/V failure (4560 Hz/V failure) ext. attempts.Stop sequence The drawings illustrate the stop sequence.0 s. this alarm is raised set to 0. Electric Power Generation Installation and maintenance 5304 en .Run feedback failure (4540 Run feedb. feedback. deactivated. The start . prepare output is activated when the start fail) sequence is initiated and deactivated when the start output is activated. prelubrication or preheating. activated when the start output activates until the specified time has expired.0 s.5 . If the timer is feedback is received. If the timer is set If running is detected on the frequency to 0. has not detected running.
Binary start input Auto mode: island operation and load takeover GB close button is pressed Manual mode 31 . Cooling Description Stop Comment down Auto mode stop X X Trip and stop alarm X X Manual.05 / c ControlReg200/ControlReg200P Stop sequence: Stop coil tCOOL Cooling down time tstop Stop coil Running feedback Sequence initiated The stop sequence will be activated if a stop command is given. The stop sequence can only be interrupted during the cooling down period. The stop sequence includes the cooling down time if the stop is a normal or controlled stop. Electric Power Generation Installation and maintenance 5304 en .2016. Auto mode: island operation and load Remove "auto start/stop" X X takeover. Emergency stop X Engine shuts down and GB opens. Interruptions can occur in these situations: Event Comment Mains failure AMF mode selected (or mode shift selected ON) and auto mode selected. Cooling down is interrupted if the Stop button on display (X) X stop button is activated twice.
Stop (6210 Stop) be the exact time it takes to get the Cooling-down: the length of the cooling.05 / c ControlReg200/ControlReg200P Setpoints related to the stop sequence reached normal cooling water temperature. MB close delay: the time from GB OFF to MB ON. in menu 6214. The GB can only be closed if the mains breaker is open.7. The reason for this could be high ambient temperature.. 6214 «Cool down temperature» before the If the cooling-down temperature is set to engine is stopped. Please refer to the description of «Breaker spring load time». The extended stop setpoint in 6214 within the time limit in sequence is activated any time the stop parameter 6211. the controller will perform the AMF sequence in case of a mains failure in load takeover or TEST mode.2016. it must be checked that the voltage and frequency are OK. and the cool-down period will . the cooling-down sequence will beneficial if the en. M-Logic. . Electric Power Generation Installation and maintenance 5304 en . Cool down controlled by engine temper- ature: the engine temperature-controlled If the cooling-down timer is set to 0. 32 . the MB ON sequence will not be initiated before this delay has expired. The MB can only be closed if the generator breaker is open. temperature below the temperature setpoint down period. If the engine has been running running feedback or the generator voltage for a long period. 7080 MB control Mode shift: when enabled. This is particularly 0 deg. temperature.0 s. Setpoints related to MB control. for a short period of time and therefore not 4. the engine cannot get feedback has disappeared until a new start the temperature below the temperature sequence is allowed. Extended stop: the delay after the running If.6 . Modbus (USB). it and frequency are still present after the will have reached normal running delay in this menu has expired. the engine will be shut button is pressed. down by this timer.Breaker sequences The breaker sequences will be activated depending on the selected mode: Mode Genset mode Breaker control Auto All Controlled by the unit Manual All Push-button. Load time: after opening of the breaker.gine has been running be entirely controlled by the timer. for some reason. Digital input Block All Controlled by the unit Before closing the breakers. cool-down is to ensure that the engine is the cooling-down sequence will be cooled down below the setpoint in menu infinite.Stop failure (4580 Stop failure) as the cool-down period will be very short or A stop failure alarm will appear if the primary none at all.
05 / c ControlReg200/ControlReg200P .7 . The timers used by the AMF function are indicated in the table below: Timer Description Menu number 7070 f mains failure tFD Mains failure delay 7060 U mains failure tFU Frequency/voltage OK 6220 Hz/V OK 7070 f mains failure tFOD Mains OK delay1 7060 U mains failure tGBC GB ON delay 6230 GB control tMBC MB ON delay 7080 MB control 1) If the generator is not in «auto» the «mains OK delay» is not used. 4.AMF MB opening (7060 U mains failure) (only for ControlReg200P) It is possible to select the functionality of the mains breaker closing function.7. This is necessary if the unit operates in Automatic Mains Failure (AMF). the MB will close immediately when the mains is OK. the engine starts. Electric Power Generation Installation and maintenance 5304 en . When a mains failure occurs. and the mains breaker engine starts at the same time. Example 1: 7065 Mains fail control: Start engine and open MB Mains OK tMBC MB ON GB ON Gen start seq tFD tFOD Gen stop seq Gen running Gen f/U OK tFU Mains failure Mains OK detected 33 . The possibilities are: Selection Description Start engine and open When a mains failure occurs. the mains breaker opens.AMF timers The time charts describe the functionality at a mains failure and at mains return. When the Start engine generator is running and the frequency and voltage are OK. the MB opens and the GB closes.2016.
2016. Electric Power Generation Installation and maintenance 5304 en . direct closing Running feedback Generator frequency/voltage OK MB open MB ON. direct opening MB open MB OFF. direct closing Mains frequency/voltage OK GB open GB OFF.05 / c ControlReg200/ControlReg200P Example 2: 7065 Mains fail control: Start engine Mains OK MB ON tMBC GB ON tGBC Gen start seq tFD Gen stop seq tFOD Gen running Gen f/U OK tFU Mains failure Mains OK detected Conditions for breaker operations The breaker sequences react depending on the breaker positions and the frequency/voltage measurements. The conditions for the ON and OFF sequences are described in the table below: Sequence Condition GB ON. direct opening Alarms with fail classes: Shut down or Trip MB alarms 34 .
The main particularity of the ControlReg200/200P is the association between the controller and a voltage 6 .General information the help-file (F1) for the Utility Software.DISPLAY AND MENU STRUCTURE 7 . which is located on LEROY-SOMER homepage Access to AVR menu under documentation for ControlReg. This section deals with the Information about engine communication description of the AVR part. 35 . The shunt excitation alternator is a simple concept and does not have a short-circuit capacity. Following are given 2 diagram for 6 leads and 12 leads alternators. 5313. Generalities: AC SUPPLY SHUNT excitation system The shunt excitation alternator is auto- excited with the ControlReg200/200P. The AVR regulation menu can be accessed via the ControlReg200/200P’s general navigation menu. or quick access to this menu can be obtained by pressing the Up and Down push-buttons (simultaneously).2016. can be found in the manual ref.ENGINE COMMUNICATION regulator. Electric Power Generation Installation and maintenance 5304 en .1 .AVR (AUTOMATIC VOLTAGE Information about configuration of the REGULATOR) FUNCTIONS view lines in the display can be found in 7.05 / c ControlReg200/ControlReg200P 5 . The AVR part controls the excitation current according to the alternator’s output voltage.
05 / c ControlReg200/ControlReg200P ControlReg200P with 12 leads alternator 36 . Electric Power Generation Installation and maintenance 5304 en .2016.
ControlReg200P with 6 leads alternator
The AVR manages the generator excitation current to ensure that the output voltage follows the
desired set point. The list below gives the characteristics of the excitation levels.
Without load: I excitation = 0.6 to 1 A
With load: maximum continuous I excitation = 4 A
Forcing (10 s): maximum I excitation = 7 A
Exciter field resistance = 10 to 30 ohm
- Around ±0.5 % for total harmonic distortion less than 5 %
- Around ±2.5 % for higher total harmonic distortion, but less than 20 %
• Power supply protected by 8 A, 250 V fast fuse, breaking capacity 30 kA
• The AVR terminals are composed by:
- E+ and E- standing for exciter stator input
- X1 and X2 standing for the AVR’s AC supply voltage.
This AC supply ranges from 90 V to 277 V 50Hz and 60 Hz single phase alternator.
A step-down transformer must be used for the higher voltages. It is used to create the
excitation current through power electronics components (diodes and IGBT).
7.2 - U/f function, volt-Hertz function
The ControlReg200/200P is equipped with engine help, which consists in reducing the voltage
according to the engine frequency.
When set to a high value, this function, called U/f, induces a greater voltage drop, and then the
resistive torque on the engine is reduced. Consequently, the speed drop is reduced and the time
response to go back to rated speed and voltage is improved. The diagram below gives an
overview of voltage profiles according to the U/f setting.
The ControlReg200/200P allows the setting of volt-Hertz function for 1.0 × U/f to 3.0 × U/f in
steps of 0.1.
7.3 - Voltage and frequency adjustment
Voltage and frequency can be adjusted with the ControlReg200/200+ HMI.
There are two possible voltage ranges:
- Low range for up to 350V operations
- High range for up to 530V applications
For all operations above 530 V, a step-down transformer is necessary. The user can select
single phase or three-phase operation through the utility software.
The diagram below describes the knee position for 50 Hz and 60 Hz operation. The knee defines
the frequency above which the voltage set point is constant. Below this knee value, the voltage
set point follows U/f law as described in the previous section.
The ControlReg allows a knee setting from 45 Hz to 65 Hz with 0.1 Hz steps.
7.4 - Soft-start function
The ControlReg200/200P can manage the way the voltage is built up owing to the soft-start
based on a timer. This timer defines how long it should take for the soft-start to increase the
voltage up to nominal voltage. Below is given an example of three different voltage start-ups
based on three different increasing soft-starts.
The soft-start can be adjusted from 0.1s to 120s in steps of 0.1s.
7.5 - ControlReg200/200P field weakening
This is applied when the user wants to manually de-excite the ControlReg200/200P.
The excitation is switched off by disconnecting the ControlReg200/200P power supply (1 wire
X1 or X2). Contact rating: 16 A - 250 V AC.
Do not reclose the power supply until the voltage has reached a value ≤15 % of the rated
voltage (approximately 5 seconds after opening).
7.6 - ControlReg200/200P field forcing
When the alternator loses its residual magnetism preventing voltage build-up, the following
diagram can be used to magnetize it again.
- The battery must be isolated from the ground.
- Exciter field may be at line potential.
Faulty rotating diodes and too low ControlReg200/200P . the return to the rated .Faulty exciter .and E+ up and its voltage is when respecting the polarity for still correct when the starting up 2 to 3 seconds (see battery is removed section regarding field The alternator starts Check the connections of the forcing) up but its voltage ControlReg200/200P voltage does not reach the sensing rated value when the battery is removed The alternator starts Faulty ControlReg200/200P up but its voltage disappears when the battery is removed Voltage too Check the drive speed Correct speed . Electric Power Generation Installation and maintenance 5304 en .Check the low ControlReg200/200P connections and settings (the product may be faulty) .7 . Check the resistance load . Check the resistance Speed too low Increase the drive speed (do not change the ControlReg200/200P settings until the correct speed is reached) Voltage too Adjust Adjustment Faulty ControlReg200/200P high ControlReg200/200P ineffective setting Voltage Adjust .Short circuit in the main when on field.Sporadic disconnection on the terminals .Check the speed (or knee correct at the voltage between E+ point set too high) no load and E.Exciter winding open circuit disappears ControlReg200/200P.05 / c ControlReg200/ControlReg200P 7.Check the speed: possibility oscillations ControlReg200/200P of cyclic irregularity PID .Rotating diodes burnt out .Faulty induced excitation during surge suppressor and value .Troubleshooting on ControlReg200/200P malfunction Fault Act Effect Check/root cause No voltage Connect a 4 to 12 V The alternator starts Lack of residual magnetism at no load battery on E.Faulty ControlReg200/200P Voltage Run at no load and check .on the . and .Main field open circuit or replace any defective short-circuited components 41 .Faulty ControlReg200/200P operation the rotating diodes.2016.Faulty exciter armature Voltage Check the The voltage does not .Main field winding short- circuited.
and the event occurs or when the running feedback starter motor will be disengaged.Start functions remove starter can be used. the running engine has reached its firing speed.1. The start sequence When the digital running feedback is active. The controller will start the genset when the Running feedback start command is given. is deactivated when the remove starter the start output is deactivated.05 / c ControlReg200/ControlReg200P 8 . RPMNOM RPM If it is not possible to activate the run status alarms at low revolutions.2 . Normally. In that case. according to the shutdown fail class. the digital running feedback is activated. 600 feedback 400 Remove starter t t Remove starter Oil pressure Running Firing speed Running The diagram illustrates how the remove starter input is activated when the engine has reached its firing speed. and the oil pressure does not reach a t level above the shutdown setpoint before Firing speed 600 RPM. and the starter motor will be disengaged. RPM RPM RPMNOM RPM 1000 Run.1 . the start output is deactivated. Remove starter When the digital remove starter input is RPM present. At the running speed. An example of a critical alarm is the oil pressure alarm. the remove starter function must be used. the digital control inputs for running detection or 8. then the genset would shut down The diagram illustrates how the digital if the specific alarm was activated at the running feedback is activated when the preset 400 RPM.2016. Electric Power Generation Installation and maintenance 5304 en . RPM The reason for having two possibilities to deactivate the start output is to be able to delay the alarms with run status. it is configured Run.Digital feedbacks 8. is present.Start functions If an external running relay is installed.1 .1.ADDITIONAL FUNCTIONS 8. feedback must be activated at a higher number of revolutions than 600 RPM. 42 . But if feedback the starter motor has to disengage at 400 RPM.
The factory setting is 1000 RPM (6170 in question must be configured as a RMI Running detect. Remove When choosing frequency running starter. input for oil pressure measurement.1.1. feedback menu RPMNOM 4301 t RPM Firing speed Run Remove starter input detection The drawing below shows how the setpoint Oil pressure of the remove starter is detected at the firing menu 6175 t speed level.3 .2016. above). the level will be configurable menu 6161 in channel 6176.Oil pressure The diagram below shows how the running The multi-inputs can be used for the feedback is detected at the firing speed detection of running feedback. t Firing speed Running 8. the running feedback is detected.4 .). The factory setting is 400 RPM (6170 Running detect. Running feedback 8.). and the start RPMNOM sequence is ended. RPM When the oil pressure increases above the adjusted value (6175 Pressure level). Firing speed 43 .Analogue tacho feedback When a magnetic pick-up (MPU) is being The number of teeth on the flywheel must used. RPMNOM The running feedback is detected by RPM either the digital input (see diagram Run. Electric Power Generation Installation and maintenance 5304 en . frequency Measurement. RPM Running feedback RPM / Oil pressure Run. MPU feedback. feedback. The terminal level. (Magnetic Pick-Up) or EIC (engine menu 4301 communication). adjusted.05 / c ControlReg200/ControlReg200P The remove starter input must be RPM configured from a number of available binary inputs. the specific level of revolutions for be adjusted in menu 6170 when the MPU deactivation of the start output can be input is used.
the length and the breaker in question will not be of breaker open signal is adjusted as the closed. GB On) and MPU or a digital input. The close breaker output will activate for a short time for the compact breaker to close. compact breaker is tripped externally. Continuous the firing speed level. When using this type of signal. GB Off). 8. the controller will use the close command (e. The close RPM breaker output will activate for a short time Run detection for closing of the circuit breaker. the controller will need to The remove starter function can use the use both a close command (e.1 . menu 6161 This type of signal will most often be used t combined with a compact breaker. the unit checks breaker to recharge the breaker.Breaker spring load time setting of breaker type for both mains To avoid breaker close failures in situations breaker and generator breaker.). GB On) and the open RPMNOM command output (e.Breaker types There are three possible selections for the 8. The breaker where breaker ON command is given before type is selected in the application the breaker spring has been loaded. an alarm will be issued.2016. incorrect (reversed).Phase sequence error breaker off output will activate for the 8.4 .g.2 .g. With the setting compact.g.2. The factory setting is NE gives a high signal when active. the configuration. With the setting pulse. Electric Power Generation Installation and maintenance 5304 en . If it is closing.3 . Pulse RPM / Oil pressure This type of signal is most often used combined with circuit breaker. Remove Compact starter. If the that the phase sequence is correct. The 44 . spring load time can be adjusted for GB and MB. an open command output (e.g. The 8. The open Oil pressure breaker output will activate for a short time menu 6175 for opening of the breaker. Continuous NE This type of signal is most often used combined with a contactor. a direct Firing speed Running controlled motor-driven breaker. the controller will only use the close breaker (e.g. it is depending on the chosen phase direction in recharged automatically before next parameter 2154: «phase rotation».05 / c ControlReg200/ControlReg200P Remove starter input output will be activated for closing of the The drawing below shows how the setpoint contactor and will be deactivated for opening of the «remove starter input» is detected at of the contactor (NO contactor). delay time for the GB/MB open failure alarm in menu 2160/2200.Description of phase sequence compact breaker to open and hold it error activated long enough for the motor in the Prior to closing a breaker. 400 RPM (6170 Running detect. GB Off). If compact breaker is selected. GB On) output.
Breaker LED indication depending on the breaker type and To alert the user that the breaker close therefore there are two available solutions: sequence has been initiated but is waiting 1.4. The setpoints are found in the and the GB is closed. feedbacks from the breakers: One for GB 3. because the spring load time must expire (or the digital input must be activated .not shown in this example). The auto start/stop input is deactivated. A load time setpoint for the GB and MB the LED indication for the breaker will be control for breakers with no feedback flashing green in this case. Then the controller issues the close signal. the controller waits a while before it issues the close signal again. The inputs are ready to close. The AUTO start/stop is reactivated immediately after the GB has opened. The genset is in auto mode.g. it will not be 1. the GB opens. Digital input the stop sequence is executed and the GB Two configurable inputs can be used for is opened. Electric Power Generation Installation and maintenance 5304 en . then the controller can If the two solutions are used together. This can be requirements are to be met before closing of controlled through timers in the controller or the breaker is allowed. Timer-controlled for permission to give the close command. the genset is running expired. After the you risk getting a close failure: breaker has been opened. 8. After the breaker has been opened. However. again before the stop sequence is finished. after it has opened. configured in the «Config menu» or with the If the breaker needs time to reload the spring PC utility software. by the operator through a switch in the switchboard. 2.05 / c ControlReg200/ControlReg200P The following describes a situation where indicating that the spring is loaded. 2.2016. it will not the GB will give a GB close failure as the GB be allowed to close again before the needs time to load the spring before it is configured inputs are active. If the auto start/stop input is activated spring loaded and one for MB spring loaded. This is what happens: When the AUTO start/stop input deactivates.Principle The diagram shows an example where a controller in island mode is controlled by the AUTO start/stop input. e. the auto start/ allowed to close again before the delay has stop input is active. both take this delay into account.1 . GB closed GB open Auto Start/stop ON Auto Start/stop OFF t [sec] Spring load time 45 . menus 6230 and 7080. through digital feedbacks from the breaker.
The inhibit functionality is a way to make an alarm inactive when the events. chosen in the menu below.5 . 46 .05 / c ControlReg200/ControlReg200P 8.Alarm inhibit In order to select when the alarms are to be active. The inhibit functionality is only available via the PC utility software. Selections for alarm inhibit: Function Description Inhibit 1 Inhibit 2 M-Logic outputs: Conditions are programmed in M-Logic Inhibit 3 GB ON (TB ON) The generator breaker is closed GB OFF (TB ON) The generator breaker is open Run status Running detected and the timer in menu 6160 expired* Not run status Running not detected or the timer in menu 6160 not expired* Generator voltage > 30% Generator voltage is above 30% of nominal Generator voltage < 30% Generator voltage is below 30% of nominal MB ON The mains breaker is closed MB OFF The mains breaker is open * The timer in 6160 is not used if binary running feedback is used. there is a drop-down window where it is possible to select which signals have to be present in order to inhibit the alarm. are active. a configurable inhibit setting for each alarm has been made. Electric Power Generation Installation and maintenance 5304 en .2016. For each alarm.
Here. the alarm will only be active when the generator is running and disabled again when the GB is closed. feedback The diagram below illustrates that after activation of the running feedback. Electric Power Generation Installation and maintenance 5304 en . Example: In this example. alarms with Run status will be t Alarms active activated.5. inhibit is set to Not run status and GB ON.Run status (6160) Alarms can be adjusted to activate only when the running feedback is active and a specific time delay has expired. Run. The timer is ignored if digital running feedback is used.05 / c ControlReg200/ControlReg200P Inhibit of the alarm is active as long as one of the selected inhibit functions are active. When the delay expires. a run status delay will expire. 47 . 8.2016.1 .
this button is not active. the display returns to the view menu system.2016. Access lock will typically be activated from a key switch installed behind the door of the switchboard cabinet. If the access lock is activated when the setup menu system is displayed. DOWN Active ESC Active * The function does not have a dedicated button on the display. Electric Power Generation Installation and maintenance 5304 en . When activated. it is not possible to access the setup menu. The setup menu system can only be entered again if the access lock is deactivated. the display will say «Access lock» when pushing the display buttons affected by the access Lock (see the table below). The input to be used for the access lock function is defined in the «Config menu» or with the PC utility software (USW). Display Button Button Comment Button icon status START Not active STOP Not active GB ON Not active GB OFF Not active MB ON Not active MB OFF Not active TEST* Not active AUTO/ Not active MAN LED Active TEST* HORN Active UP Active SELECT Active If the access lock is activated when the view menu system is displayed. 48 . After three minutes.6 .05 / c ControlReg200/ControlReg200P 8.Access lock The purpose of access lock is to deny the operator the possibility to configure the unit parameters and change the running modes from the display or digital inputs.
TH. start and stop. TH . the command timers are ignored.SA. SA. The time-dependent commands are flags that are raised when the command timer is in the active period. Electric Power Generation Installation and maintenance 5304 en . enable «modeshift» and set genset mode to LTO. SU . The command timers are available in M-Logic and can be used for other purposes than starting and stopping the genset automatically. WE.MO. TU. WE. Up to four command timers can be used for e. SU To start in AUTO mode.Individual days (MO. TU.2016. To combine AMF and the use of command timers. FR .MO. The settings can either be set up through the PC utility software or the display. SU) . If auto mode is activated. SA. TU.g.05 / c ControlReg200/ControlReg200P The following digital input functions are affected when access lock is activated: Digital input name Input status Remote Start Not active Remote Stop Not active Remote GB ON Not active Remote GB OFF Not active Remote MB ON Not active Remote MB OFF Not active Test mode Not active Auto mode Not active Manual mode Not active Block Not active 8. Each command timer can be set for the following time periods: .g. WE. 49 . TH. TU.7 . TH. When set in AMF mode. FR.MO. this function is available in island operation and load takeover operation. FR. the «Auto start/stop» command can be programmed in M-Logic or in the input settings. start and stop the genset automatically at specific times each weekday or certain weekdays. WE.Command timers The purpose of the command timers is to be able to e.
Running output 6160 Run status can be adjusted to give a digital output when the genset is running.05 / c ControlReg200/ControlReg200P 8. but no alarm will appear. 50 . If the output function is not changed to «limit» function.2016. Then the output will activate.8 . Electric Power Generation Installation and maintenance 5304 en . Change the output function to «limit» in the output menu (Menu 5000). an alarm will appear at every running situation. Select the wanted digital output in output A and output B and enable the function.
Two timers are available. These inputs must be configured through the Utility software: N° Input Description This input is used to change between idle speed and nominal speed. It will not be able to stop 2 Temperature control input as long as this input is activated. the low speed input is overruled. Electric Power Generation Installation and maintenance 5304 en . The main purpose of the function is to prevent the genset from stopping.Idle running 8.9 .9.2016. The speed governor must be prepared for the idle run function if this function is to be used. Turbo chargers not originally prepared for operating in the low speed area can be damaged if the genset is running in «idle run» for too long. Start/stop genset High/low speed selection Low speed Idle run input input relay ControlReg GOVERNOR Temperature control input Actuator 51 . the genset will start. The final user is in charge of modifying the speed of the genset directly on the fuel injection system. until the temperature has reached an acceptable level or the timer is over. To use temperature control it is necessary to enable idle speed in parameter 6295. If the idle run function is selected by means of the timer.Idle running The purpose of the idle run function is to change the start and stop sequences to allow the genset to operate under low temperature conditions. This input does not prevent the genset from stopping . 8.9.05 / c ControlReg200/ControlReg200P 8. The function is typically used in installations where the genset is exposed to low temperatures which could generate starting problems or damage the genset. The idea is to make the genset run enough time and heat up before it is loaded. This input is typically used in combination with a monitoring of temperature. When the function is enabled. This function is required when gensets are used in very cold conditions. Just after start 1 Low speed up of genset. It has to be noted that the governor itself must handle the idle speed based on a binary signal from the unit (see the principle diagram below). and one timer is used in the stop sequence. It is possible to use the idle run function with or without timers. One timer is used in the start sequence. locking down the genset to idle input speed. When this input is activated.Description The function is enabled and configured in 6290 Idle running.it is only a selection between idle and nominal speed. The timers are available to make the function flexible. this input will be activated.2 .1 . two digital inputs are used for control purposes. or a timer.
The start and stop sequences are changed in order to let the genset stay at the idle level before speeding up. If the genset is to be prevented from stopping.9.2016. 52 . It also decreases the speed to the idle level for a specified delay time before stopping. In that case the characteristic looks like this: RPM 1500 300 t Start Stop The oil pressure alarm (RMI oil) will be enabled during idle run if set to «ON».05 / c ControlReg200/ControlReg200P 8. then the digital input «temp control» must be left ON at all times.Examples Idle speed during starting and stopping In this example both the start and the stop timers are activated. RPM 1500 tSTART tSTOP 300 t Start Stop Idle speed. no stopping In this example both timers are deactivated. Electric Power Generation Installation and maintenance 5304 en .3 .
7 . 8.Running signal The running feedback must be activated when the genset is running in idle mode. except for the oil pressure alarms. Electric Power Generation Installation and maintenance 5304 en . RMI oil 6.5 .Start Start No Auto start/stop ON No Yes No starting Temp control ON Start the Yes Genset Start the Genset No Idle timer on Yes Lowspeed ON No Yes Timer expired Yes Genset running Genset running at f Nom at idle speed End 53 .9. 8.9. 8.9.Inhibit The alarms that are deactivated by the inhibit function are inhibited in the usual manner.9.7 and 8 which are active during «idle run» as well.05 / c ControlReg200/ControlReg200P 8.Idle speed flowcharts The flowcharts illustrate the starting and stopping of the genset by use of the inputs «temp control» and «low speed».6 .2016.4 .
Setpoint: this setpoint +/.Stop Start Auto No No Temp control Genset running start/stop OFF at idle speed OFF Yes Yes Genset stop sequence No Idle timer on Lowspeed No Yes ON Yes Genset running No Idle timer at idle speed expired Yes Genset stop sequence End 8.Hysteresis: this decides how big a deviation from the setpoint is needed to activate/deactivate the engine heater. The setpoints adjusted in menu 6320 are: .10 . .Enable: enables the engine heater function. 54 . . Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 8.Output A: the output for the engine heater.9.Engine heater This function is used to control the temperature of the engine.the hysteresis is the start and stop points for the engine heater. A sensor measuring the cooling water temperature is used to activate an external heating system to keep the engine at a minimum temperature. . .2016.8 .Input type: multi-input to be used for temperature measurement.
.Enable: enable/disable the ventilation function.Output A (OA): the output activated when the setpoint is exceeded. an alarm will be raised if configured in menu 6330. The type of input to use for the temperature measurement is selected in menu 6323 Engine heater.Engine heater alarm If the temperature keeps dropping after the start setpoint has been exceeded.Setpoint: the limit for activation of the output set in OA. The purpose is to use a multi-input for measuring the cooling water temperature and that way activate an external ventilation system to keep the engine below a maximum temperature.1 . 95°C 85°C Relay 55 .2016. .05 / c ControlReg200/ControlReg200P Principle diagram: 43°C 37°C Engine heater Relay Start attempt DG running The engine heater function is only active when the engine is stopped.Hysteresis: the number of degrees the temperature has to be below the setpoint in order to deactivate the output set in OA. Setpoints available (6460 Max ventilation): . Electric Power Generation Installation and maintenance 5304 en .10.Ventilation This function can be used to control the cooling of the engine. 8.11 . . 8. The functionality is shown in the below diagram.
6554 Output A The selected output activates below the start limit and deactivates above the stop level. start Fuel transfer pump start point in percentage.2016. stop Fuel transfer pump stopping point in percentage.12 . Setpoints available in menu 6550: The fuel pump output can be activated via M-Logic.11.05 / c ControlReg200/ControlReg200P 8.Max. The output to be used for control of the fuel pump. The below drawing shows how the fuel pump is activated when the level reaches 20% and stopped again when the level has reached 80%.Fuel pump logic The fuel pump logic is used to start and stop the fuel supply pump to maintain the fuel level in the service tank at predefined levels. Parameter Name Function 6551 Fuel pump log. 6553 Fuel fill check Delay timer before activating fuel fill check alarm. an alarm will be raised when. ventilation alarm Two alarms can be set up in menu 6470 and menu 6480 to activate if the temperature keeps rising after the start setpoint has been reached. Electric Power Generation Installation and maintenance 5304 en .ever the output is activated. Otherwise. 8.1 . 6556 Fail class The fail class of the fuel fill alarm. 6552 Fuel pump log. The start and stop limits are detected from one of the multi- inputs. The output should be configured as a «limit» output. 6555 Type Choose multi-input if 4-20 mA is used. The multi-input or external analogue input to be used for the fuel level sensor. Fuel level Fuel service tank level 80% 20% Time Fuel pump start level Fuel pump stop level 56 . Choose «auto detection» if an RMI is used.
Fail class 8. Trip of Trip of Cooling down Stop Fail class horn display excite(3) GB MB genset genset 1 Block X X 2 Warning X X 3 Trip GB X X X 4 Trip + stop X X X X X 5 Trip + stop + X X X X X X de-excite(1) 6 Shutdown X X X X 7 Trip MB (2) X X X 8 Trip MB/GB(2) X X (X) X 57 . the fuel level must increase by 2% within the fuel fill check timer set in menu 6553. The tables below illustrate the action of each fail class when the engine is running or stopped. When the fuel pump is running.2016.2 .12.1 .Engine running Alarm Alarm De.13 .Fuel fill check The fuel pump logic includes a Fuel fill check function.13. If the fuel level does not increase by 2% within the adjusted delay time.05 / c ControlReg200/ControlReg200P 8.13. then the fuel pump output deactivates and a Fuel fill alarm occurs. 8. 2% ∆ level. Electric Power Generation Installation and maintenance 5304 en . Eight different fail classes can be used.Fail class All activated alarms must be configured with a fail class.1 . 8. 2% tFill check The level of increase is fixed at 2% and cannot be changed. The fail classes define the category of the alarms and the subsequent alarm action. ∆ level.
(3) Excitation is deactivated as long as the alarm is present. 8.13.The alarm horn output will activate . for instance.3 .The alarm will be displayed in the alarm info screen . .Engine stopped Fail class Action Block engine start Block MB sequence Block GB sequence 1 Block X 2 Warning 3 Trip GB X X 4 Trip + stop X X 5 Trip + stop + de-excite X X 6 Shutdown X X 7 Trip MB(1) X 8 Trip MB/GB(1) X(2) X X(2) In addition to the actions defined by the fail classes. the following actions occur. If. (1) The fail classes «Trip MB» and «Trip MB/GB» is only accessible on ControlReg200P. (2) The fail class «Trip MB/GB» will only block engine start and GB sequence if no mains breaker is present.05 / c ControlReg200/ControlReg200P The table illustrates the action of the fail classes.The generator breaker will open instantly .The genset is stopped instantly .The genset cannot be started from the unit (see next table) (1) Alarms configured with the failclass «Trip+stop+de-excite» cannot be removed before engine is stopped. (2) The fail classes «Trip MB» and «Trip MB/GB» is only accessible on ControlReg200P.2016. Electric Power Generation Installation and maintenance 5304 en . it is possible to activate one or two outputs if additional outputs are available in the unit. The fail class «Trip MB/GB» will only trip the generator breaker if there is no mains breaker present. 58 . an alarm has been configured with the «shutdown» fail class.
14 . Setpoints available in menus 6110 and 6120: Enable: enable/disable the alarm function. The running hours is counting when the running feedback is present. The service timer alarm will be activated at 8:00 AM on the day the alarm expires. The service timers are set up in menus 6110 and 6120. This must be done when the alarm is activated. To change the fail class via the PC software.13. the unit will display an alarm. 8. Fail class: the fail class of the alarm. the alarm will still be activated. The service timer alarm will be activated as soon as the running hours have been reached. The function is based on running hours. Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 8. 59 .Service timers The unit is able to monitor the maintenance intervals. Two service timers are available to cover different intervals. Select the desired fail class in the fail class drop-down panel.Fail class configuration The fail class can be selected for each alarm function either via the display or the PC software. Reset: enabling this will reset the service timer to zero.4 . When the adjusted time expires.2016. Output A: the output to be activated when the alarm is activated. Day: the number of days to activate the alarm – if the running hours are not reached before this number of days. the alarm function to be configured must be selected. Running hours: the number of running hours to activate the alarm.
Digital inputs The unit has a number of binary inputs. some of which are configurable and some are not. 60 . Electric Power Generation Installation and maintenance 5304 en .15 . it will automatically be stated as «digital» in the «Config menu» when using the display.05 / c ControlReg200/ControlReg200P 8. Input function Auto Test Man Block Configurable Input type 1 Shutdown override X X X X Configurable Constant 2 Access lock X X X X Configurable Constant 3 Binary running detection X X X X Configurable Constant 4 Remote start X Configurable Pulse 5 Remote stop X Configurable Pulse 6 Test X X X Configurable Pulse 7 Auto X X X Configurable Pulse 8 Manual X X Configurable Pulse 9 Block X X X Configurable Constant 10 Remote GB ON X Configurable Pulse 11 Remote GB OFF X Configurable Pulse 12 Remote MB ON X Configurable Pulse 13 Remote MB OFF X Configurable Pulse 14 Remote alarm acknowledge X X X X Configurable Constant 15 Auto start/stop X Configurable Constant 16 Remove starter X X X Configurable Constant 17 GB position ON X X X X Configurable Constant 18 GB position OFF X X X X Configurable Constant 19 MB position ON X X X X Configurable Constant 20 MB position OFF X X X X Configurable Constant 21 Emergency stop X X X X Not configurable Constant 22 Low speed X X Configurable Constant 23 Temperature control X X Configurable Constant 24 GB close inhibit X X X Configurable Constant 25 MB close inhibit X X X X Configurable Constant 26 GB spring loaded X X X X Configurable Constant 27 MB spring loaded X X X X Configurable Constant 28 Inhibit Engine alarms X X X X Configurable Constant 29 Digital (1) X X X X Configurable (1) If an input terminal is set to be a binary input without being assigned an input.2016.
Binary running detection alarm LED on the display stops flashing. 18. Acknowledges all present alarms. The start sequence is deactivated. but it can be configured in be initiated when manual mode is selected.Functional description 10. 5. the «start» output is deactivated. When the input is activated. channel 6201. The unit 8. The mains breaker ON sequence will be Menu 6200 (shutdown override) is hidden initiated and the breaker will close if the GB until the function is chosen as an input.1 . the the generator breaker position. manual. opened or a position failure alarm occurs.2016.15. load genset when manual mode is selected. Block (GB position OFF) Changes the present running mode to block. The genset will start when this input is activated. Remote alarm acknowledge and the log. Shutdown override The generator breaker ON sequence will be initiated and the breaker will close if the MB This input deactivates all protections except is opened when manual mode is selected.05 / c ControlReg200/ControlReg200P 8. Electric Power Generation Installation and maintenance 5304 en . 17. takeover and the AUTO running mode is selected. and the 6. The unit running mode cannot be changed by requires this feedback when the breaker is activating the digital inputs. This means the start output deactivates. Remote MB ON sequence after an activation of this input. Generator breaker open feedback 9. Remote GB ON 1. Auto start/stop the engine. Auto (GB position ON) Changes the present running mode to auto. 61 . Generator breaker closed feedback 7. parameter 6202. Remove starter genset when manual mode is selected. The input is used as a running indication of 15. and the 3. When this input is 11. the overspeed protection and the emergency stop input. the number of start attempts is The generator breaker OFF sequence will seven by default. 2. Remote stop This input initiates the stop sequence of the 16. It will only initiated when manual mode is selected. is opened when manual mode is selected. Test starter motor will disengage. The input function is used as an indication of the generator breaker position. The input can be used This input initiates the start sequence of the when the unit is in island operation. Also a special cool down timer.. The genset will be stopped if the 4. is used in the stop 12. be possible to view measurements. The input function is used as an indication of When block mode is selected. Remote start input is deactivated. Manual requires this feedback when the breaker is Changes the present running mode to closed or a position failure alarm occurs. alarms 14. Access lock 13. Remote MB OFF Activating the access lock input deactivates The mains breaker OFF sequence will be the control display push-buttons. Changes the present running mode to test. Remote GB OFF activated.
then the genset in this. The controller will not send a close signal before this feedback is present.2016. then the mains 21. Multi input Type Function 14 Binary Digital 15 Binary Digital 16 Binary Digital 17 Binary Digital 18 Binary Digital 19 Binary Digital 62 . MB close inhibit a position failure alarm occurs. then the mains breaker position. 27. GB spring loaded immediately. 24. or it stops (low speed = OFF). Low speed The controller will not send a close signal Disables the regulators and keeps the before this feedback is present. When the input is deactivated. MB spring loaded 22. Emergency stop breaker cannot close. PLC or other equipment the mains breaker position. The unit requires controls when load is on gen-set.05 / c ControlReg200/ControlReg200P 19. It starts at high or low speed. Electric Power Generation Installation and maintenance 5304 en . The input shuts down the engine 26. PC utility software. The unit requires the genset goes to idle mode (low speed = this feedback when the breaker is closed or ON). 28. engine interface alarms. then the position OFF) generator breaker cannot close. The shutdown fail class must be selected. Inhibit EI alarms The governor must be prepared for this When this input is active. Mains breaker closed feedback (MB starts. 23. The default configuration of the multi inputs are like in the table below. a position failure alarm occurs. genset running at a low RPM. position ON) depending on the activation of the low speed The input function is used as an indication of input. Inhibit used The input function is used as an indication of for GB. please refer to «Help» When the input is high. At the same time it opens the generator breaker. Mains breaker open feedback (MB When this input is activated. GB close inhibit 20. it will inhibit all function. this feedback when the breaker is opened or 25. where ext. Temperature control The input functions are set up with the This input is part of the idle mode function. When this input is activated.
1 . 4. GB on The function will close the generator breaker.05 / c ControlReg200/ControlReg200P 8. Electric Power Generation Installation and maintenance 5304 en . it will stay closed in the ext. 5. 3. it will be active until the reset horn push-button is activated or the alarm(s) has (have) been acknowledged. and when no running feedback is present. The output will be active for the time programmed in parameter 6181. 63 . Starter (Crank) The output configured to «starter» will be active for the time selected in parameter 6183 in the start sequence. Status OK The output configured to «Status OK» is active as long as the device is working properly.16. 7.Outputs The unit has a number of output functions which can be configured to any available output terminal. stop time (parameter 6212). 2. the horn output will be active for the time configured in the parameter 6131 «Alarm horn». If 6131 is set to 0 seconds. Prepare This function will activate the output as the first thing in the start sequence. Output function Auto Test Man Block Configurable Output type 1 Status OK X X X X Configurable Constant 2 Run coil X X X X Configurable Constant 3 Stop coil X X X X Configurable Constant 4 Prepare X X X X Configurable Constant 5 Starter (Crank) X X X X Configurable Constant 6 Horn X X X X Configurable Constant 7 GB on X X X X Configurable Continuous 8 GB off X X X X Configurable Continuous 9 MB on (1) X X X X Configurable Continuous 10 MB off (1) X X X X Configurable Continuous 11 D+ (Battery charge) X X X X Fixed Constant (1) The output functions «MB on» and «MB off» is only available with ControlReg200P. 6. This function is used for preheating the engine or for prelubrication. 8. Run Coil The output configured to «Run coil» will be closed the entire time the engine is supposed to run. This means that every time an alarm state appears. regardless of fail class.2016. Stop Coil This output will close to stop the engine. Horn The «horn» output is a common alarm output.16 .Functional description 1.
Binary The configuration of the function of each for multi-inputs is done using the «config menu» on the display.Multi-inputs The ControlReg unit has six multi-inputs which can be configured to be used as the following input types: 1. Input number Channel Multi-input 14 10980 Multi-input 15 10990 Multi-input 16 11000 Multi-input 17 11300 Multi-input 18 11310 Multi-input 19 11160 64 . 10. 4-20 mA 2. D+ (Battery charge) D+ is the activation of the battery charge alternator. GB off This function will open the generator breaker. MB off (ControlReg200P only) This function will open the mains breaker. The channel numbers used are following the below table.1 . or in the «USW» tab in the PC tool. RMI water temperature 6. Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 8. 11.17. RMI fuel level 7. RMI oil pressure 5.Multi-inputs 8. When running feedback is present. 9. Pt100 3.17 . Pt1000 4. MB on (ControlReg200P only) This function will close the mains breaker.2016. Table of default output settings: Output Function 7 Starter (crank) 8 Run coil 9 GB ON 10 Not used 11 Not used D+ Battery charge activation/feedback 8. this is no longer an output but a feedback for battery charge.
If configured as 4-20 mA. 8.05 / c ControlReg200/ControlReg200P For each input. .RMI fuel: fuel level sensor For each of the RMI functions.g.2016. The inputs have different functions. Offset parameter is used for compensation of wire resistance.RMI oil This RMI input is used for measuring the lubricating oil pressure. 8.Pt100/Pt1000 This input type can be used for heat sensor.3 .5 . The text will be «Multi input HW limit».17.17. it is possible to select between different characteristics including a configurable one. The alarm is raised when any of the multi- inputs has raised the level of destruction for current. two alarm levels are available. cooling water temperature. as the hardware design allows for several RMI types. The ControlReg200 handles an overcurrent protection for the multi-inputs.4 . These various types of RMI are available for all multi-inputs: . the menu numbers of the alarm settings for each multi-input is controlled by the configured input type as seen in the following table. the unit range of the measured value corresponding to 4-20 mA can be changed in the PC utility software in order to get the correct reading in the display.RMI oil: oil pressure . Multi input Multi input Multi input Multi input Multi input Multi input Type 14 15 16 17 18 19 4-20mA 4120/4130 4250/4260 4380/4390 4740/4750 4770/4780 4800/4810 PT100/1000 4160/4170 4290/4300 4420/4430 4740/4750 4770/4780 4800/4810 RMI oil 4180/4190 4310/4320 4440/4450 4740/4750 4770/4780 4800/4810 RMI water 4200/4210 4330/4340 4460/4470 4740/4750 4770/4780 4800/4810 RMI fuel 4220/4230 4350/4360 4480/4490 4740/4750 4770/4780 4800/4810 Binary 3400 3410 3420 3430 3440 3450 Only one alarm level is available for the binary input type.RMI water: cooling water temperature . in order to protect the HW. and the current flow is above 24 mA. The unit of the measured value can be changed from Celsius to Fahrenheit in the PC utility software in order to get the desired reading in the display. the input will automatically switch to resistive mode.Sensor type 1 = VDO .2 . 8. 8.17.Sensor type 2 = VDO 65 .RMI inputs The unit can contain up to 6 RMI (resistance measurement input). e.4-20 mA If one of the multi-inputs has been configured as 4-20 mA.17. but no channel will be used. RMI is a resistance measurement input which can be used together with a resistance dependent sensor. Electric Power Generation Installation and maintenance 5304 en . an alarm will be displayed. If the current seen from the unit reaches this level.
5 7 27.0 87 124.1 71.0 58 151. Please refer to the Application Notes for further wiring information.2 90 47 6.2 0.0 145 184.0 51.0 116 155. The resistance as well as the pressure can be adjusted.8 40 123 3.3 4.2 2.5 36 99.8 70 74 5.05 / c ControlReg200/ControlReg200P .9 2.0 29 81.9 89.0 The configurable type is configurable with eight points in the range 0-2500 Ω. If any voltage is applied to the RMI inputs. then be aware that no voltage must be connected to the input.0 15 44.6 4.0 44 117.7 4.9 100 33 7.2016.7 10 200 1.4 8.2 10. Electric Power Generation Installation and maintenance 5304 en .3 5.0 107.0 73 184.1 60 88 4. If the RMI input is used as a level switch.0 102 140.3 1.4 50 103 3.0 131 170.9 31.7 9.5 2.Sensor type 4 = ESP-100 RMI sensor type Pressure Type 1 Type 2 Type 3 Type 4 Configurable RMI Bar psi Ω Ω Not used Ω Ω 0 0 10.3 6. 66 . it will be damaged.0 3.5 22 62.5 80 60 6.5 51 134.4 20 165 1.0 240 0.5 65 168.1 30 135 2.0 10.
1 321 80 176 70. 67 .0 222.Sensor type 4 = EST-250 RMI sensor type Temperature Type 1 Type 2 Type 3 Type 4 Configurable RMI °C °F Ω Ω Ω Ω Ω 0 32 7208 10 50 4115 20 68 2529 30 86 1594 40 104 291.6 .2016.8 7.0 460 70 158 97.4 11.3 1029 50 122 197.Sensor type 1 = VDO .4 74 130 266 28.2 164 100 212 38.7 69.1 47.7 120 110 230 29.05 / c ControlReg200/ControlReg200P 8. .1 113.Sensor type 3 = VDO .3 323.5 480.2 The configurable type is configurable with eight points in the range 0-2500 Ω. If the RMI input is used as a level switch. If any voltage is applied to the RMI inputs.4 36. then be aware that no voltage must be connected to the input.2 19.Sensor type 2 = VDO .17.5 36. Please refer to the Application Notes for further wiring information.5 62. The temperature as well as the resistance can be adjusted.6 89 120 248 22. it will be damaged.8 40 150 302 18.RMI water This RMI input is used for measuring the cooling water temperature.1 157.6 680 60 140 134.9 52 140 284 22. Electric Power Generation Installation and maintenance 5304 en .2 83.8 227 90 194 51.
05 / c ControlReg200/ControlReg200P 8. 8.Sensor type 4 = ESF RMI sensor type Fuel level Type 1 Type 2 Type 3 Type 4 Configurable RMI % Ω Ω Not used Ω 0 78.Illustration of configurable inputs Resistance (Ω) Setpoint 8 Setpoint 7 Setpoint 6 Setpoint 5 Setpoint 4 Setpoint 3 Setpoint 2 Setpoint 1 Value 1 2 3 4 5 6 7 8 (bar.RMI fuel This RMI input is used for the fuel level sensor.17. If any voltage is applied to the RMI inputs.8 .2016.Sensor type 1 = VDO .6 180 33 If the RMI input is used as a level switch. The value as well as the resistance can be adjusted.17. The configurable type is configurable with eight points in the range 0-2500 Ω.Sensor type 2 = VDO .7 . . °C or %) Setpoints 68 . Electric Power Generation Installation and maintenance 5304 en .8 3 240 25 147 50 103 75 60 100 1. then be aware that no voltage must be connected to the input. it will be damaged.
Scaling of 4-20 mA inputs The scaling of the analogue inputs is made to ensure that the readout of the inputs is made with a resolution that fits the connected sensor. but only in the PC utility software.05 / c ControlReg200/ControlReg200P 8. 8. 15 and 16. Electric Power Generation Installation and maintenance 5304 en .10 . Adjust the input resistance value to fit the desired output value for each eight points. Scaling example: 1.2016.17. in this example multi-input 14 (parameter 10980). Read the parameters from the device. It is recommended to follow the guide below when changing the scaling of the analogue inputs. 69 .Configuration The eight curve settings for the configurable RMI inputs cannot be changed in the display. 2. The configurable sensor type is only available for multi-input 14.9 . Both parameters (input and output) for each of the eight points can be individually adjusted. Use the utility software to configure a multi-input to be 4-20 mA. The screenshot below illustrates an example of values for the eight configurable points on the configurable curve for RMI 14. In the PC utility software the configurable inputs are adjusted in the tab regarding the actual RMI-input.17.
Electric Power Generation Installation and maintenance 5304 en . 0-5 bar: The display will then show 0 at 4 mA. e. The three dots to the left of the figures. 70 . After reading the parameters. Adjust the input as required. Adjust the input as required. the 4-20 mA alarm appears in the «analogue» tab in the USW.g. are buttons.g.05 / c ControlReg200/ControlReg200P 3. e. The example below shows how to adjust the analogue input alarm. 0-5 bar: 4. marked with arrows.2016.
In the example shown above. the parameter file should be uploaded from the device to the PC and then saved.18 .17. If needed. The possible selections of the input function are normally open or normally closed. the alarm has been scaled so it needs to be adjusted (0-5 in this example). After reading the parameters.2016.11 . The display will now show the scaled value of multi-input 6. it would still only be possible to adjust the setpoint without decimals. 6. the input function will be «NC». It is necessary to read the parameters from the device to the computer after changing the scale (1/1. A checkmark in the «high alarm»-box is equal to the input function «NO» and if the box is unchecked.Input function selection Digital input alarms can be configured with a possibility to select when the alarms are to be activated. 1/10 or 1/100) settings. and this is also a scaling of the value on the display.Binarys If the multi-inputs are configured to «Binary». they become available as binary inputs. 7. In the USW this will be handled with a checkmark in the tick-box «high alarm». This is in order to refresh the parameter list so the alarm settings present the correct value. 8. Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 5. 8. Save the parameter file: After having set up the 4-20 mA inputs (HW as well as alarms). 71 . If the parameters were not refreshed. it is possible to scale the input to fit the sensor (Parameter 11010). the value can be adjusted with two decimals. In this way. the settings will not be modified again if the parameters are reloaded to the device.
Digital input alarm configured to NO. > highest resistance Level switch Only active if the switch is open Binary input Only active if the wire is broken. Not implemented - RMI Fuel. > 97 ohm RMI Fuel. > 195 ohm RMI Oil. The output function can be selected to be ND (Normally De-energized). type 2 < 1 ohm .05 / c ControlReg200/ControlReg200P The drawing below illustrates a digital input used as an alarm input. does not work for a short circuit 72 .3 ohm . > 7208 ohm RMI Fuel. > 488 ohm RMI Temp. type 1 < 0. NE (Normally Energized). An alarm with a configurable fail class will be activated. normally open. > 1941 ohm RMI Oil. > 194. type 1 < 4 ohm . type 2 < 4 ohm . This will initiate an alarm when the signal on the digital input appears. > 195 ohm RMI Oil. Limit or Horn.6 ohm . type 4 < 33 ohm .19 . Electric Power Generation Installation and maintenance 5304 en . type 2 < 1 ohm . then it is possible to enable the wire break function for each input. If the measured value on the input is outside the normal dynamic area of the input.1 ohm Pt1000 < 823 ohm . > 240 ohm RMI Temp. type 3 < 0. Digital input alarm configured to NC.Wire fail detection If it is necessary to supervise the sensors/wires connected to the multi-inputs. type 4 < 33 ohm . > 195 ohm RMI Fuel.V DC 8. Not implemented - RMI Oil. This will initiate an alarm when the signal on the digital input disappears. type 3 .2016. 2. type 4 < 40 ohm . Input Wire failure area Normal range Wire failure area 4-20 mA < 4 mA 4-20 mA > 20 mA Pt100 < 82. type 3 . > 240 ohm RMI configurable < lowest resistance . 1. > 97 ohm RMI Temp. normally closed.6 ohm . type 1 < 1 ohm . it will be detected as if the wire has made a short-circuit or a break. > 488 ohm RMI Temp. ControlReg Series Relay output Digital input Alarm input .
It is not possible to make language configuration from the display. the measured value will drop to zero. Electric Power Generation Installation and maintenance 5304 en . In addition to the master language. three different languages can be configured. and it cannot be changed.b. Input signal (mA. 8.05 / c ControlReg200/ControlReg200P Principle The illustration below shows that when the wire of the input breaks. This is the default language.21 . Then the alarm will occur. °C. When the languages are configured with the USW. It is delivered with one master language which is English. it is possible to choose whether the wire fail detection is active only in the event of «open circuit». but the already configured languages can be selected. %) Wire failure Upper failure limit Lower failure limit Wire failure t Wire break For any analogue inputs.Language selection The unit has the possibility to display different languages.Text in status line This table explains the different messages in the status line text.20 . 73 . they can be selected in the system setup menu 6080. This is done via «translations» in the PC utility software. «short circuit» or if it should be active in both events. 8.2016.
05 / c ControlReg200/ControlReg200P 8.1 . The configurable input is active RIDE ACCESS LOCK The configurable input is activated. GB open and an active "Trip GB" alarm SHUTDOWN OVER. The genset will not stop until a timer has expired IDLE RUN ###.2016. Electric Power Generation Installation and maintenance 5304 en .21.Standard texts Condition Comment BLOCK Block mode is activated FULL TEST Test mode is activated FULL TEST ###.#min The timer in the "Idle run"’ function is active START PREPARE The start prepare output is activated START RELAY ON The start output is activated START RELAY OFF The start output is deactivated during the start sequence MAINS FAILURE Mains failure and mains failure timer expired 74 .#minTest mode activated and test timer counting down ISLAND MAN Genset stopped or running and no other action taking place READY ISLAND AUTO Genset stopped in Auto ISLAND ACTIVE Genset running in Auto AMF MAN Genset stopped or running and no other action taking place READY AMF AUTO Genset stopped in Auto AMF ACTIVE Genset running in Auto LOAD TAKEOVER Genset stopped or running and no other MAN action taking place READY LTO AUTO Genset stopped in Auto LTO ACTIVE Genset running in Auto DG BLOCKED FOR Generator stopped and active alarm(s) on START the generator GB ON BLOCKED Generator running. and the operator tries to activate one of the blocked keys GB TRIP EXTERNALLY Some external equipment has tripped the An external trip is breaker logged in the event log MB TRIP EXTERNALLY Some external equipment has tripped the An external trip is breaker logged in the event log IDLE RUN The "Idle run" function is active.
Text in mains units MAINS U OK DEL Mains voltage is OK after a mains failure The timer shown is the ####s Mains OK delay MAINS f OK DEL ####s Mains frequency is OK after a mains The timer shown is the failure Mains OK delay Hz/V OK IN ###s The voltage and frequency on the When the timer runs out genset is OK it is allowed to operate the generator breaker COOLING DOWN ###s Cooling-down period is activated COOLING DOWN Cooling-down period is activated and Cooling down timer is infinite set to 0.Counters Counters for various values are included. 6106 Start attempts Offset adjustment of the number Counting at each start attempt of start attempts Additional counters for «Running hours» and «Energy» can be read out from the PC utility software. and some of these can be adjusted if necessary. Electric Power Generation Installation and maintenance 5304 en .its Mains failure delay. 75 . The table shows the adjustable values and their function in menu 6100: Description Function Comment 6101 Running time Offset adjustment of the total Counting when the running running hours counter feedback is present 6102 Running time Offset adjustment of the total Counting when the running running thousand hours counter feedback is present 6103 GB operations Offset adjustment of the number Counting at each GB close of generator breaker operations command 6104 MB operations Offset adjustment of the number Counting at each MB close of mains breaker operations command 6105 kWh reset Resets the kWh counter Automatically resets to OFF after the reset.0 s GENSET STOPPING This info is shown when cooling down has finished EXT.05 / c ControlReg200/ControlReg200P Condition Comment MAINS FAILURE IN Frequency or voltage measurement is The timer shown is the ###s outside the lim. for instance if the unit is installed on an existing genset or a new circuit breaker has been installed. The reset function cannot be left active. STOP TIME ###s 8.22 .2016.
If no busbar voltage transformer is present. values for the generator. A variety of the outputs can also The nominal settings can be changed to be selected. and at the activation of those inputs. only only very simple commands are needed. If the delay timer in of nominal settings. the unit will use this actual data. and they are adjusted in menus 6000 to 6030 (Nominal The M-Logic is part of the PC utility settings 1 to 4). 8. change match different voltages and frequencies. the unit will operate M-Logic is not a PLC but substitutes one. 8. half of the parameter file has been M-Logic is a simple tool based on logic downloaded when the communication is events. digital means that if the buzzer is going to be used input or menu 6006.Buzzer Activation The ControlReg200 has a built-in buzzer. of genset modes and change of running The controller has four sets of nominal modes.Nominal settings the defined output will occur. the buzzer will be active input among the input events. they can be configured in the PC Utility software and adjusted in menus 6050 to 6060. A great variety of inputs can be selected. of operating the generator control system. such as digital 8. M-Logic is used to execute different Safety commands at predefined conditions.How to change the nominal inputs. Electric Power Generation Installation and maintenance 5304 en . as a horn annunciator. The purpose is to be able to remote-monitor and control the genset application. This setpoints can be done in two ways. Please see the M-Logic manual.USW communication It is possible to communicate with the unit via the PC utility software. file. 8.M-Logic Application settings The M-Logic functionality is included in the Please refer to the PC utility software help unit and is not an option-dependent function.24 .26. nominal settings in the outputs. then set the primary and The main purpose of M-Logic is to give the secondary side values to the same value operator/designer more flexible possibilities as generator nominal value.1 . defined. not via the display. such as digital outputs.26 . Select the required M-Logic is used. where switching of this configuration tool. If e. the input must be set Binary input to «Horn» and the output must be set to M-Logic is used when a binary input is «Buzzer». alarm conditions and running settings conditions. 76 . and as such.23 . between 50 and 60 Hz is required.25 . and select the after this time delay. The possibility to switch between the Please refer to the «Help» function in the four sets of nominal setpoints is typically PC utility software for a full description used on rental gensets. If communication fails. it can only be nominal settings for the busbar. The switching between the nominal The buzzer is configured in M-Logic.2016.g. There are also two sets of software. The buzzer will act concurrently needed for switching between the four sets to the horn output timer. One or more input conditions are interrupted.05 / c ControlReg200/ControlReg200P 8. if according to the received data.
Changing the voltage scaling will also influence the nominal power scaling: Nom. input no. Electric Power Generation Installation and maintenance 5304 en .0-900.0 kV All nominal values and the primary VT settings must be corrected after the scaling has been changed in menu 9030. 8.4 kV-75 kV 0.0 V-2500.0 V-2500.0 kW 10.00 kV 10 kV-160 kV 1. parameter 9030 parameter 9030 6051 and 6053 10 V-2500 V 1. settings 1 to 4 Nom.0-900. To be able to handle applications above 25000 V and below 100 V.Scaling Default voltage scaling is set to range 100 V-25000 V (menu 9030).14 or Not used or Not used Set nom.27 . Setup of the scaling can be done in menu 9030 from the display. settings 1 to 4 Transformer ratio Scaling (power) will change (voltage) will change settings parameter 9030 according to according to parameter 6041. it is necessary to adjust the input range so it matches the actual value of the primary voltage transformer. parameter settings 1 Not Dig. input no.0 V 10.0 V 100 V-25000 V 10-20000 kW 100 V-25000 V 100 V-25000 V 0.4 kV-75.14 or Not used or Not used Set nom. 77 .10-90.00 kV 0. This makes it possible to support a wide range of voltage and power values. parameter settings 2 Menu settings In menu 6006 the switching is made between settings 1 to 4 simply by choosing the desired nominal setting.0 kV-160.00 MW 0.05 / c ControlReg200/ControlReg200P Example: Event A Event B Event C Output Dig.4 kV-75.0 MW 10.2016.0 kV 10.0 kV-160.
Before filter Differential Differential PB limit Alarm ∆ P=PA-PB After filter PA Timer value Three different differential measurements between two analogue input values can be configured. As an example the figure below shows the two parameters for input selection for differential measurement 1.05 / c ControlReg200/ControlReg200P 8. available inputs are: .28 .EIC measurements 78 . If the differential value drops below the setpoint value before the timer runs out. Electric Power Generation Installation and maintenance 5304 en . If the differential function is for example air filter check. Inputs are selected from the input list as shown below.Differential measurement With the differential measurement function it is possible to compare two analogue inputs and trigger on the difference between the two values.Multi inputs . the timer will be activated if the setpoint between PA (analogue A) and PB (analogue B) is exceeded.2016. Differential measurements between two sensors can be configured in menus 4600-4606. then the timer will be stopped and reset.
Below figure shows the two parameters to configure alarm level 1 and 2. please refer to online documentation. For more information. Each alarm can be configured in two alarm levels for each differential measurement between analog input A and input B. 8.05 / c ControlReg200/ControlReg200P The relevant alarm setpoint is chosen in parameters 4610-4660.29 . Electric Power Generation Installation and maintenance 5304 en .Filename extension The filename extension for ControlReg200 products are .2cr It will be possible to update the firmware using the utility software and use the normal procedure. for differential measurement 1. 79 .2016.
General The protections are all of the definite time type. Example: A power generation system must not reconnect to a network when the voltage is 85% of Un +/-0% < U < 110% +/-0%. the measuring class of the controller and an adequate «safety» margin has to be taken into consideration. If the function is e. Phase-phase voltage trip The voltage alarms are working based on phase-phase measurements.PROTECTIONS 9. Timer setting Setpoint Timer Timer Timer Alarm start reset start When the timer runs out. It is not possible to select phase-neutral measurements.05 / c ControlReg200/ControlReg200P 9 . i. then the timer will be stopped and reset. Electric Power Generation Installation and maintenance 5304 en . 80 . Therefore it cannot be considered as a short-circuit protection. When parameterizing the controller.e. the output is activated. the timer will be activated if the setpoint is exceeded. a setpoint and time is selected. If the voltage value falls below the setpoint value before the timer runs out. a control unit’s tolerance/accuracy has to be taken into consideration.2016. In order to ensure reconnection within this interval. It is recommended to set a control unit’s setting range 1-2% higher/lower than the actual setpoint if the tolerance of the interval is +/-0% to ensure that the power system does not reconnect outside the interval. The total delay will be the delay setting + the reaction time. overvoltage. The overcurrent level is limited to 200% of the nominal current.g.1 .
2016. even though the alarm setpoint is 10% in both cases.05 / c ControlReg200/ControlReg200P Phase-neutral Phase-phase UL3-L1 UL1-N UL1-L2 UL3-L1 UL1-N UL1-L2 U U U 3-N 2-N U 3-N 2-N UL2-L3 UL2-L3 As indicated in the vector diagram. 10% error 380/207 360/185 The alarm will occur at two different voltage levels. Example : the below 400V AC system shows that the phase-neutral voltage must change 20%. The table shows the actual measurements at a 10% undervoltage situation in a 400/230 volt system. Phase-neutral Phase-phase Nominal voltage 400/230 400/230 Voltage. Electric Power Generation Installation and maintenance 5304 en . Example: 20% UNOM = 400/230V AC Error situation: UL1L2 = 360V AC UL3-L1 UL1-L2 UL3L1 = 360V AC UL1-N UL1-N = 185V AC ΔUPH-N = 20% U U 3-N 2-N UL2-L3 Both the generator protections and the busbar/mains protections use phase-phase voltage. when the phase-phase voltage changes 40 volts (10%). 81 .neutral voltage and the phase-phase voltage. there is a difference in voltage values at an error situation for the phase.
This means that if the voltage drops.2016.05 / c ControlReg200/ControlReg200P 9.60. Timer value can be adjusted in the range 0. e. Electric Power Generation Installation and maintenance 5304 en . The result can be expressed as a curve function where the voltage setpoints are fixed values and the current setpoints can be adjusted (menu 1100).2 . Voltage and current % values refer to the nominal settings. the generator can only produce part of its usual rating.1.0 sec.Voltage-dependent (restraint) overcurrent This protection is used when the generator must be tripped due to a fault situation that creates a reduced generator voltage. During the voltage collapse. the current values can be adjusted in the range 50-200%. the overcurrent setpoint will also drop. The protection will be activated based on the overcurrent setpoint as a function of the measured voltage on the generator voltage terminals.g. a voltage collapse. 200 190 180 170 % Nominal Current 160 150 140 130 120 110 100 50 60 70 80 90 100 % Nominal Voltage The voltage values for the six points on the curve are fixed. 82 . A short-circuit current during a voltage collapse can even be lower than the nominal current rating.
3000-3610. 9000-9150. please see the separate document dealing with the parameters list ref. Electric Power Generation Installation and maintenance 5304 en . 4120-4970.00 mm H × W = 3.62» × 4.Unit dimensions and panel cutout The unit is designed for mounting in the panel front. 5346 availabe on Leroy Somer webpage. For further information.MOUNTING The unit is designed for flush mounting by means of four fixing brackets ensuring IP65. 5000-5070.41» + 0. 7000-7680.00 + 1.Front view 132 mm 112 mm 83 . the panel door must be cut out according to the following measurements: H × W = 92. 11. 11. 6000-6990. In order to ensure optimum mounting.1 .05 / c ControlReg200/ControlReg200P 10 .04» The useful sizes are given below. 2010-2790.2016. 11 .00 × 112.PARAMETERS LIST This documents is relative to the parameters 1000-1990.1.1 .
2 .2016.Top view 132 mm 112 mm 11.1.3 . Electric Power Generation Installation and maintenance 5304 en .05 / c ControlReg200/ControlReg200P 11.Right side view 92 mm 112 mm 84 .1.
05 / c ControlReg200/ControlReg200P 11.2 .5 Nm.Tightening torques Unit panel door mounting: 0.2016.3 Nm.Caution on brackets mounting Two different brackets are given in the accessories pocket included in the package: • 2 « BOT/TOP » mounting brackets identified by B and T letters • 2 « LEFT/RIGHT » mounting brackets identified by L and R letters Note: make sure that the each bracket is placed with respect of the labelling. 2. Below is the way the 4 screws (M4x16 type) are fitted to the bracket.7 lb-in Plug connections (terminals): 0. 4. 11.4 lb-in 85 .3 . Electric Power Generation Installation and maintenance 5304 en . Non respect of these recommendations may lead to damage the brackets.
major plastic components. These materials can be reclaimed through a combination of manual dismantling. 86 . Current Transformers (176). including the Automatic Voltage Regulator (198). These components are usually marked with plastic type information. Recyclable materials Our alternators are mainly built out of iron. .diode Bridge (343) and Surge suppressor (347). Waste & hazardous materials The following components and materials need a special treatment and need to be separated from the alternator before the recycling process: . system should be considered as a hazardous These instructions are for information waste and has to be handled according to purposes only. found on the alternator rotor. sourcing and products design to improve The oil and grease from the lubrication recyclability and diminish our footprint. steel and copper materials. It is the user responsibility to local legislation. Electric Power Generation Installation and maintenance 5304 en . interference suppression module (199) and other semi-conductors. We continuously reclaimable material and should be handed survey our production processes. Our technical support depar- tment can provide detailed directions on products dismounting upon request. which can be reclaimed for recycling purposes. such as the terminal box structure on some products. material to specialized disposal companies.electronic materials found in the terminal box. .05 / c ControlReg200/ControlReg200P Disposal and recycling instructions All materials listed above need special We are committed to limit the environmental treatment to separate waste from impact of our activity. comply with local legislation regarding product disposal and recycling. mechanical separation and melting processes.2016.
Where we can help: Conception •Consulting & specification •Maintenance contracts Life Extension •Remanufacturing Start-up •System upgrade •Commissioning •Training Optimization •Monitoring Operation •System audit •Genuine spare parts •Repair services Contact us: Americas: +1 (507) 625 4011 Europe & International: +33 238 609 908 Asia Pacific: +65 6263 6334 China: +86 591 88373036 India: +91 806 726 4867 Scan the code or go to: service. This local presence is our guarantee for fast and efficient repair.co/support .epg@leroy-somer. support and maintenance services.lrsm.com www. Trust your alternator maintenance and support to electric power generation experts. We know alternators operation inside out. Our field personnel are 100% qualified and fully trained to operate in all environments and on all machine types. Service & Support Our worldwide service network of over 80 facilities is at your service. providing the best value service to optimize your cost of ownership.
emersonindustrial.com www.emerson.2016. www.05 / c .com/epg 5304 en .
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