specification hw of control system unigen ap...using “bridge tem” is possible to read values...

Ing. Z.Královský Ing. Petr ŠtolPetr 457 Okrajová 1356675 22 STA 674 01 T EBÍ

Development & production of control equipment Tel.: 568 870982 Tel.: 568 421453Visualization, measurement and regulation SW Fax: 568 870982 Cell: 777 753753WWW.UNIMA-KS.CZ [email protected] e-mail: [email protected] e-mail: [email protected]

Specification HW of control system

UniGEN AP

April 2015HW V9

http://WWW.UNIMA-KS.CZ

mailto:[email protected]



Specification UniGEN1

1. Operating Conditions ......................................................................................... 2

2. Using ................................................................................................................... 22.1 Firmware CHP .................................................................................................. 22.2 Firmware TEM .................................................................................................. 22.3 Firmware ORC .................................................................................................. 22.4 Firmware MVE .................................................................................................. 2

3. Mechanical Design ............................................................................................. 2

4. Electrical Design ................................................................................................ 34.1 Connector SREL (binary relay outputs) ............................................................ 44.2 Connector SBOA (binary outputs the open collectors) ..................................... 54.3 Connector SBOB ((binary outputs the open collectors+ PWM) ........................ 54.4 Connector SSTM (step motor) .......................................................................... 64.5 Connector SBIA (binary inputs) ........................................................................ 74.6 Connector SBIB (binary inputs) ........................................................................ 74.7 Connector SAIA (analogical inputs 50mV) ....................................................... 84.8 Connector SAIB (analogical inputs 20mA) ....................................................... 84.9 Connector SAIC (analogical inputs Pt100) ....................................................... 94.10 Connector SAID (analogical inputs 10V) ........................................................ 104.11 Analogue Inputs Calibration ........................................................................... 114.12 Connector SAO (analogical output) ................................................................ 124.13 Connector SWW (actuator Woodward) .......................................................... 124.14 Connector SVC (voltage regulation) ............................................................... 134.15 Connector SSC (rotation speed control) ......................................................... 134.16 Connector SRPM (rpm measuring) ................................................................. 134.17 Connector SGV (generator voltage) ............................................................... 144.18 Connector SMV (net voltage) ......................................................................... 144.19 Connector SGC (generator current) ............................................................... 154.20 Connector SMC (net current – consumption measuring) ................................ 154.21 Connector SCAN (communication interfacing CAN) ....................................... 164.22 Connector SMBS (Communication RS-485 ModBUS) .................................... 164.23 Connector SUNI (Communication RS-485 UnimaBUS) .................................. 164.24 Connector SPWR (power supply) ................................................................... 164.25 Connector CANNON (RS-232) ....................................................................... 17

5. I/O expansion .................................................................................................... 185.1 Expansion modules......................................................................................... 185.2 Read information from neighbor devices ........................................................ 18

6. Ethernet socket settings (IP address) ............................................................ 19

7. Configuration .................................................................................................... 28


1. Operating ConditionsTo enjoy the faultless operation it is necessary to observe the fundamental

operating conditions which are defined in the following sections:a) Proper connecting of Input/Output connectorsb) CU-power supply which meets the allowed tolerancesc) Proper parameter setting of the master SWd) Observance of the operating temperature in surroundings of up to 60°C

2. UsingControl system is designed to control motor-generator sets with phasing

generators to the distribution network, supports different modes of cooperation withthe network contains network protection, generator and motor protections.With user-defined functions (gates, flip-flops, analog members, PID controllers,control blocks for three-way valves, etc.) is possible the basic firmware easilyextended with additional functionality (see documentation "ManagerAP a mappingfunction") ..

Using communication bus can be connected to control system expansionmodules of inputs and outputs, speed controller USC, UIS voltage regulator, ignitionUIS1÷4. All these components can be parameterized by one service program"ManagerAP" over a single connection to the control system. CU have these devicesexchange the necessary information, so in addition to the communication bus is notnecessary to further interconnection components.

2.1 Firmware CHPIn version "CHP" is designed for management of cogeneration units.

2.2 Firmware TEMIn version “TEM” is designed for management of cogeneration units with TEM

Evo controllers. Using “Bridge TEM” is possible to read values from TEM Evo tocontroller.

2.3 Firmware ORCIn version "ORC" is designed for control of ORC units.

2.4 Firmware MVEIn version "MVE" is designed for control of small hydro power plants.

3. Mechanical DesignCU is placed in an independent metal enclosure having dimensions

290x185mm (+5mm sealing rubber on periphery), height 95 mm. The size ofassembly hole is 175x275. Connectors for connection of all signals are placed alongthe rear part of CU periphery, connector for ethernet connection is situated abeam,in ca 30mm distance from the front panel inside.

Front panel of CU include keyboard and graphics display 240x180pixels withdiagonal 130mm (5,1”).


4. Electrical Design

CU is connected to the switch board by means of connectors PA256 (spacing5,08), ARKZ 1550 (spacing 3,81) and BLZ7,62/90 (spacing 7,62). The CU isenergized either with DC voltage of 10-33V or with AC voltage of 8-24V.

CANNON-connector is used for connection of CU to PC (monitoring, setting,diagnostics), for the same purpose is used also the Ethernet socket by use of whichit is possible to communicate via the network

Connector lay-out:

Note: Till HW version V8 were SMC and SMC connectors next to each other layer connectors. Since HW version V9 is at the otherconnector layer only SGC (measuring current generator), SMC connector (measuring current network) from the CU side under SGCconnector. The new connectors have a larger pitch and allow for connection cables with a larger cross-section than the original ones.


4.1 Connector SREL (binary relay outputs)Pin Name DescriptionSREL.1 BinOut1A Configurable physical binary output

(Relay contacts for binary output 1)SREL.2 BinOut1BSREL.3 BinOut2A Configurable physical binary output

(Relay contacts for binary output 2)SREL.4 BinOut2BConnector span: 5,04mmMax. conductor cross-sect.: 2,5mm2

El. Parameters of contact : 8A/250V AC/30V DCContact resistance: 100m (1A/6V DC)Electrical endurance: 1x105 OPS

Spare internal wiring diagram:

BinOut1..2GND

SBOA (BinOut)


4.2Connector SBOA (binary outputs the open collectors)Pin Name DescriptionSBOA.1 BinOut3 Configurable physical binary outputsSBOA.2 BinOut4SBOA.3 BinOut5SBOA.4 BinOut6SBOA.5 BinOut7SBOA.6 BinOut8Connector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

El. Parameters of output : Open collector 50mA/60V DC

4.3Connector SBOB ((binary outputs the open collectors+ PWM)Pin Name DescriptionSBOB.1 BinOut9 Configurable physical binary outputsSBOB.2 BinOut10SBOB.3 BinOut11SBOB.4 BinOut12SBOB.5 BinOut13SBOB.6 BinOut14SBOB.7 BinOut15 Configurable physical binary output or PWMSBOB.8 BinOut16 Configurable physical binary output or PWMSBOB.9 GND Common contactConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

El. parameters of output : Common collector 50mA/60V DC


+12V

BinOut3..16GND

SBOA/B (BinOut)


4.4Connector SSTM (step motor)Pin Name DescriptionSSTM.1 L1A Coil L1 of the step motorSSTM.2 L1BSSTM.3 L2A Coil L2 of the step motorSSTM.4 L2BConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

El. parameters of output : Optional value of the optional current 40mA÷600mA


-0.6÷0.6AL1A

L2A

L1B

L2B

SSTM


4.5Connector SBIA (binary inputs)Pin Name DescriptionSBIA.1 BinIn1 Configurable physical binary inputsSBIA.2 BinIn2SBIA.3 BinIn3SBIA.4 BinIn4SBIA.5 BinIn5SBIA.6 BinIn6SBIA.7 BinIn7SBIA.8 BinIn8SBIA.9 GND Common contactConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

El. parameters of inputs : - Isolated input with line control Rv=3K3- Uout =12V/5V output voltage- Uext =+/- 50V max. ext. voltage (which does not harm input)

4.6Connector SBIB (binary inputs)Pin Name DescriptionSBIB.1 BinIn9 Configurable physical binary inputsSBIB.2 BinIn10SBIB.3 BinIn11SBIB.4 BinIn12SBIB.5 BinIn13SBIB.6 BinIn14SBIB.7 BinIn15SBIB.8 BinIn16SBIB.9 GND Common contactConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

El. parameters of inputs : - Isolated input with line control Rv=3K3- Uout =12V/5V output voltage- Uext =+/- 50V max. ext. voltage (which does not harm input)


+12V

2.0mABinIn1..10

GND

SBIA/B (BinIn)


4.7Connector SAIA (analogical inputs 50mV)Pin Name DescriptionSAIA.1 AnlIn1+ Configurable physical analogical inputs 50mVSAIA.2 AnlIn1-SAIA.3 AnlIn2+SAIA.4 AnlIn2-SAIA.5 AnlIn3+SAIA.6 AnlIn3-SAIA.7 AnlIn4+SAIA.8 AnlIn4-Connector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

Electrical parameters: Convertor resolution 13 bits, symmetric measuring


100k

AnlIn1..4+AnlIn1..4-

Thermocouple

SAIA (50mV)

4.8Connector SAIB (analogical inputs 20mA)Pin Name DescriptionSAIB.1 AnlIn5 Configurable physical analogical inputs 20mASAIB.2 GNDSAIB.3 AnlIn6SAIB.4 GNDSAIB.5 AnlIn7SAIB.6 GNDSAIB.7 AnlIn8+ Configurable physical analogical input 20mA

(differential)SAIB.8 AnlIn8-Connector span: 3,81mmMax. conductor cross-sect.: 1,5mm2



10ohm

OUTVcc AnlIn8+

AnlIn5..7

AnlIn8-

GND

SAIB (20mA)


4.9Connector SAIC (analogical inputs Pt100)Pin Name DescriptionSAIC.1 AnlIn9 Configurable physical analogical inputs Pt100SAIC.2 GNDSAIC.3 AnlIn10SAIC.4 GNDSAIC.5 AnlIn11SAIC.6 GNDSAIC.7 AnlIn12SAIC.8 GNDConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

Electrical parameters: Convertor resolution 13 bits


+12V

2.5mAAnlIn9..12

GNDPt100

SAIC (Pt100)


4.10Connector SAID (analogical inputs 10V)Pin Name DescriptionSAID.1 AnlIn13 Configurable physical analogical inputs 10VSAID.2 GNDSAID.3 AnlIn14SAID.4 GNDConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2



4.11Analogue Inputs CalibrationAll analogue inputs (20mA, Pt100, actuator position….) can be calibrated

digitally without interference with CU (trimmer setting).Calibration is carried out by service SW ManagerAP. The selected parameter

can be accurately set to desired value using press buttons for offset change andamplitude change:

Offset resetting Offset change Amplitude change

Measured value

Actual value

Recommended procedure for calibrating:

a) Disconnecting of the calibrated input (zero setting)b) Offset zero setting by “O” (eventually offset correction using “+” and “-”c) Connecting the input to the defined valued) Setting of the required value using buttons “+” and “–“ for gain correcting (or

using “G” button after enter of defined value)


4.12Connector SAO (analogical output)Pin Name DescriptionSAO.1 AnlOut Configurable physical analogical output 10V/20mASAO.2 GNDConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

El. parameters of output : Through shorting jumper optional output 10V/20mA,Voltage output shows a max. output current of 5 mA

Position of the shorting jumper for selection output 20mA

Position of the shorting jumper for selection output 10V


AnlOutGND

SAO

-20÷20mA

-10÷10V

4.13Connector SWW (actuator Woodward)Pin Name DescriptionSWW.1 PosIn Feed-back measuring for position of act. WoodwardSWW.2 GNDSWW.3 GND PWM-output for control over position of act. WoodwardSWW.3 PwmOutConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2


4.14Connector SVC (voltage regulation)Pin Name DescriptionSVC.1 RegU+ Output for direct control over the voltage regulatorSVC.2 RegU-Connector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

Insulation strength 2,5kV


SVC

RegU+RegU-

-10÷10V

4.15Connector SSC (rotation speed control)Pin Name DescriptionSSC.1 Uout10V Output for analogical speed control regulator (provided

Speedcon not assigned)SSC.2 UoutRSSC.3 GNDConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2


Uout10VUoutRGND

10k

SSC

-10÷10V

4.16Connector SRPM (rpm measuring)Pin Name DescriptionSRPM.1 RPM Input for measuring rotation speed of the aggregate. In case

of connecting of the speed governot USC the data transfer ispossible (another sensor for doing this is needless)

SPRM.2 GND

Connector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

El. Parameters: Hysteretic comparator toggle on ±0.5V


4.17Connector SGV (generator voltage)Pin Name DescriptionSGV.1 L1 Inputs for connection of the generator three phase

voltageSGV.2 L2SGV.3 L3SGV.4 NConnector span: 7,62mmMax. conductor cross-sect.: 2,5mm2

Max.voltage: 600VRated impulse: 6kVClassifications: EC001284, EC0026370

4.18Connector SMV (net voltage)Pin Name DescriptionSMV.1 L1 Inputs for connection of the net three phase voltageSMV.2 L2SMV.3 L3SMV.4 NConnector span: 7,62mmMax. conductor cross-sect.: 2,5mm2

Max.voltage: 600VRated impulse: 6kVClassifications: EC001284, EC0026370


1ML1..3N

SGV/SMV


4.19Connector SGC (generator current)Pin Name DescriptionSGC.1 L1K Inputs for connection of the generator three phase

currentSGC.2 L1LSGC.3 L2KSGC.4 L2LSGC.5 L3KSGC.6 L3LConnector span: 5,08mmMax. conductor cross-sect.: 2,5mm2

Max.current: 5APermanent curr.overload: 8AShort.curr.overload: 10AStandard references: EN60998-1; EN60998-2-1

4.20Connector SMC (net current – consumption measuring)Pin Name DescriptionSMC.1 L1K Inputs for connection of the net three phase currentSMC.2 L1LSMC.3 L2KSMC.4 L2LSMC.5 L3KSMC.6 L3LConnector span: 5,08mmMax. conductor cross-sect.: 2,5mm2

Max.current: 5APermanent curr.overload: 8AShort.curr.overload: 10AStandard references: EN60998-1; EN60998-2-1


N/5AL1..3LL1..3K

SGC/SMC


4.21Connector SCAN (communication interfacing CAN)Pin Name DescriptionSCAN.1 CANH Communication interfacing CANSCAN.2 COMSCAN.3 CANLConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

4.22Connector SMBS (Communication RS-485 ModBUS)Pin Name DescriptionSMBS.1 485A Communication interfacing RS-485 for data

communication with an master unit as well as info-????from the CU

SMBS.2 COMSMBS.3 485BConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

4.23Connector SUNI (Communication RS-485 UnimaBUS)Pin Name DescriptionSUNI.1 485A Communication interfacing RS-485 for connecting of

other devices UNIMA-KS (Speed governor USC, ignitionUIS, voltage regulator UVR, expansion modules e.t.c.)

SUNI.2 COMSUNI.3 485BConnector span: 3,81mmMax. conductor cross-sect.: 1,5mm2

4.24Connector SPWR (power supply)Pin Name DescriptionSPWR.1 POWER Supply voltage 10÷33V DC or 8÷24V AC. Next to the

supply connector is situated a safety-fuse 2A, 230V.SPWR.2Connector span: 5,04mmMax. conductor cross-sect.: 2,5mm2


1G/35

2A

SPWR


4.25Connector CANNON (RS-232)Pin Name DescriptionCAN.2 RxD Communication interfacing RS-232 for CU to PC

(visualization, setting, calibration with Manager-program). For connection can be also used the net-cableand ethernet-sockets.

CAN.3 TxDCAN.5 GND

Cable connection to connect CU to PC:

PC 3 TxD 3 CU UniGEN2 RxD 27 78 86 61 14 49 95 GND 5

Communication interface RS-232 and Ethernet interfaces share a one UART, so it isnot possible simultaneous connection of both. If you must connect a remote PC (viaethernet) and local PC (via RS-232) can be used to connect the PC RS-232 one ofthe connected expansion module (if the control system is connected via a commonbus RS-485).


5. I/O expansion

5.1Expansion modulesWith communication RS-485 can increase the number of inputs and outputs

binary and analogue expansion modules. Expansion modules are always 8-input (8-output).

The expansion module digital inputs and outputs can combine inputs / outputs(each pin is independently configurable as input or output).

The expansion module analogue inputs can be independently configuredinput type (50mV, 1V, 10V, 20mA, 100ohm, Pt100, Pt1000).

Expansion module analogue output is fixed 8x10V.

The control system can be connected up to 7 of the input modules (whetherdigital or analogue, when the binary module configured to at least one input can beconsidered as the input), and up to eight output modules. Each module must havethe same address as the control system and unique slot number (1 to 15).

Each module contains its own configurable PLC, each module can send to thecontrol system 8 digital and 8 analogue information (based on binary inputs can becreated one analogue information, that the control system can reads)

5.2Read information from neighbor devicesIn the control system can be mapped and signals from peripheral devices

(speed controller USC, UVR voltage regulator, ignition UIS etc.), it is theoreticallypossible to extend the inputs and outputs of the control system available inputs andoutputs on the speed controller, voltage or ignition. Each device can read up to 8signals from surrounding devices other than expansion modules.


6. Ethernet socket settings (IP address)Before connection of controller to network, IP address should be set. Defaultaddress is 10.0.0.195, port 10195. Next example describe change of address to192.168.111.101 and port 10196 (specific IP address, of course, is given byassigned address in the local network).Before setting must terminate communication (disconnect the RS-232 orEthernet).During UniGEN power-up press together keys „7“ and „2“, until following screen atUniGEN display will show:

MAC address 00204AA6ABCDSoftware vevsion V6.5.0.7 (070919)XPTEXEPress Enter for Setup Mode

Within a few seconds, you must press ENTER on the control system to enter the setmode.. Wait until the text on display will stop scrolling and show settings menu:

….….0 Server1 Channel 13 E-mail5 Expert6 Security7 Defaults8 Exit without save9 Save and exit Yourchoice?

Press key 0 (Server) on UniGEN and next will appear:

0 Server1 Channel 13 E-mail5 Expert6 Security7 Defaults8 Exit without save9 Save and exit Yourchoice? 0IP Address (192)

If in the brackets is a number other than 192, enter corret number, if there is already192, just press Enter, an additional number of IP addresses will show:


0 Server1 Channel 13 E-mail5 Expert6 Security7 Defaults8 Exit without save9 Save and exit Yourchoice? 0IP Address (192).(168)

If in the next brackets will appear 168, just press ENTER, otherwise press corrent168 on keyboard. By the same way set all four digits of the IP address of192.168.111.101

0 Server1 Channel 13 E-mail5 Expert6 Security7 Defaults8 Exit without save9 Save and exit Yourchoice? 0IP Address (192).(168).(111).(101)

After entering the last number of IP addresses as the next choice:


Set Gateway IP Address (N) ?

All of the following options are only slow gradually confirm by pressing of ENTERkey until the menu will appear again (about 3xENTER, depend on firmware version).


In some cases (depend on router type) is appropriate also set the gate addres. Isuch case do not press on “Set Gateway IP addresss (N)” ENTER, but cursor keyright (right mean “Yes”):


Set Gateway IP Address (N) ? YGateway IP addr (000)

Subsequently possible enter the gate address as well as IP address above. Thefollowing is the subnet mask question. Select number 8 and ENTER for the usualmask 255.255.255.0.


Set Gateway IP Address (N) ? YGateway IP addr (192).(168).(111).(001)Netmask: Number of Bits for Host Part(0=default) (0) 8

Mask settings is followed by DNS address settings. After cursor key right (“Yes”), ispossible to set DNS address as well as IP or gateway address. Skip DNS settingsusing cursor key left (“No”).


All next selections skip by ENETER key until main menu will appear:

0 Server1 Channel 13 E-mail5 Expert6 Security7 Defaults8 Exit without save9 Save and exit Yourchoice?

Than press option 9 (Save and exit) and new IP address is saved.

0 Server1 Channel 13 E-mail5 Expert6 Security7 Defaults8 Exit without save9 Save and exit Yourchoice? 9Parameters stored …

Finally turn off and on the power of UniGEN to exit IB setting mode. UniGEN will"normally" start to life…


Another setting is conveniently performed using a computer connected to the controlsystem via Ethernet (LAN). Starts the web browser and enter the new address192.168.111.101 (or use UniGEN default address 10.0.0.195 if were not changed).All this settings should be already set by UniGEN producer. Is posible (if needed) tochange UniGEN communication port e.g.

IP address of computer have to be set in the same IP address range (e.g.192.168.111.100) !

After pressing ENTER, the login dialog will appear (In the title bar will not default 10.0.0.195but 192.168.111.101):

No username or password is not necessary to enter, just press "OK" to start internetbridge settings:


Selects the "Network" and all entries are set as follows:

If an item did not agree and were changed, you must press the "OK"Next is selected in the "Serial Settings" and check the (correct) settings:


When changing some items need to press OK to confirm.


In addition, check the settings in the menu "Connection":

After change any item, press OK again to confirm.


If all agree, choose "Apply Settings" and changes of the settings are saved.

Saving takes a while, then restarts IB and settings is complete. For remote internetaccess is necessary to set the router address translation ("NAT").


7. ConfigurationVizualization, configuration and parametrization of CU is done by ManagerAPservice program.More in following documents

ManagerAP user manul.pdf ManagerAP mapping and functions.pdf

specification hw of control system unigen ap...using “bridge tem” is possible to read values...

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