OPERATION INSTRUCTIONS, PLC SYSTEM

SANAA SOUTH 30 MW EXTENSION, YEMEN

Drawn 05.08.2006 / MKa
Checked JÅ
Approved BK
Project KD06.5055
Revision No. - / 03.04.2006 / GS
Pages 1….26

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OPERATION INSTRUCTIONS, PLC SYSTEM

PLC USER’S MANUAL

This is a manual for Wärtsilä Power Plants PLC System. Purpose of the PLC system is
to control the operations of the engine and all auxiliary units connected to the PLC.
PLC also collects all available data and transfers it to WOIS Human-Machine-Interface
(HMI) system for monitoring purposes. This manual describes the main operations and
structure of PLC system.

LIST OF APPENDIXES.......................................................................................................4

1. PLC SYSTEM OVERVIEW .......................................................................................... 5

1.1 HARDWARE OVERVIEW................................................................................................................ 5
1.2 GENSET PLC ............................................................................................................................. 6
1.3 COMMON PLC............................................................................................................................ 6
1.4 COMMUNICATION ........................................................................................................................ 7
2. STARTING SEQUENCE .............................................................................................. 8
2.1 STARTING THE ENGINE ................................................................................................................ 8
2.1.1 Starting conditions.............................................................................................................................. 8
2.1.2 Starting of the 38 engine .................................................................................................................... 8
2.1.3 Starting failure .................................................................................................................................... 9
2.2 SYNCHRONIZING ......................................................................................................................... 9
2.2.1 Synchronizing in AUTO mode............................................................................................................ 9
2.2.2 Synchronizing in MANUAL mode....................................................................................................... 9
2.2.3 Synchronizing conditions ................................................................................................................... 9
2.2.4 Synchronizer position....................................................................................................................... 10
2.3 RUNNING MODES ...................................................................................................................... 11
2.3.1 KW control (Parallel with grid).......................................................................................................... 11
2.3.2 Droop control (Parallel with grid or island mode) ............................................................................. 11
2.3.3 Isochronous control (Island mode) .................................................................................................. 11
2.4 UNLOADING AND STOPPING ....................................................................................................... 11
2.4.1 Unloading ......................................................................................................................................... 11
2.4.2 Stopping ........................................................................................................................................... 12

3. ACTIVE POWER CONTROL ....................................................................................... 12

3.1 DERATING MEASUREMENTS ....................................................................................................... 13
3.2 REDUCING THE ACTIVE POWER .................................................................................................. 13
4. REACTIVE POWER CONTROL (COS PHI CONTROL).................................................... 14

5. GRID SYNCHRONIZING ............................................................................................ 14

6. GENERATOR BREAKER TRIP AND ENGINE SHUTDOWN .............................................. 14

6.1 GENERATOR BREAKER TRIP ...................................................................................................... 14
6.2 ENGINE SHUTDOWN .................................................................................................................. 15
6.3 DETECTING PRIMARY REASON ................................................................................................... 16
7. ENGINE LOAD REDUCTION ...................................................................................... 16

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8. ENGINE AUTOSTOP ................................................................................................ 17

8.1 PARALLEL WITH GRID IN AUTO MODE ........................................................................................ 17
8.2 OTHER RUN MODES .................................................................................................................. 18
9. OTHER CONTROLS ................................................................................................. 19
9.1 CONTROLS OF THE COMMON PLC............................................................................................. 19
9.1.1 HFO buffer tank filling valve control ................................................................................................. 19
9.1.2 LFO tansfer pump control ................................................................................................................ 19
9.1.3 Control of black start generator.......................................................... Error! Bookmark not defined.
9.1.4 Control of black start breaker............................................................. Error! Bookmark not defined.
9.1.5 Control of the breakers BFA901 Q3, Q4, Q5 and BFA902 Q3, Q4, Q5Error! Bookmark not defined.
9.2 CONTROLS OF THE GENSET PLC .............................................................................................. 20
9.2.1 Radiator control................................................................................................................................ 20
9.2.2 Ventilation fans control..................................................................................................................... 20
9.2.3 Prelube pump control....................................................................................................................... 20
9.2.4 Control of the main fuel valve .......................................................................................................... 20
9.2.5 Control of the booster pumps........................................................................................................... 20
9.2.6 Booster module quick closing valve control ..................................................................................... 20

10. TROUBLESHOOTING ............................................................................................. 21

10.1 BATTERY LOW CHARGE ALARM ............................................................................................... 21
10.2 PROGRAM NOT RUNNING ......................................................................................................... 21
10.3 VAMP260 OR REM543 COMMUNICATION FAILURE ALARM ....................................................... 21
10.4 COMMUNICATION FAILURE BETWEEN PLCS.............................................................................. 21
10.5 SENSOR FAULT ....................................................................................................................... 22
10.6 CARD FAILURES...................................................................................................................... 22
10.7 REPLACING CPU.................................................................................................................... 23
11. APPLICATION AND EXECUTIVE LOADER ................................................................. 23
11.1 GENERAL ............................................................................................................................... 23
11.2 POWER OFF AND ON ............................................................................................................. 23
11.3 KEY ....................................................................................................................................... 24
11.4 CONNECT TO PLC AND START THE CPU .................................................................................. 24
11.4.1 Connect to PLC.............................................................................................................................. 24
11.4.2 Start controller................................................................................................................................ 24
11.5 DOWNLOAD APPLICATION ....................................................................................................... 25
11.6 DOWNLOAD PLC EXECUTIVE AND APPLICATION ....................................................................... 25

LIST OF APPENDICES

1. PLC system layout (KD06.5055-206/-), appendix 3.1.

2. Common PLC system (KD06.5055-206/-), appendix 3.2.
3. Genset PLC system for 18V32 engine (KD06.5055-17/-), appendix 3.3.

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1. PLC System overview

PLC-system collects all I/O:s connected to IO cards, executes controls, generates
alarms and performs measurement scaling for WOIS operator station. WOIS reads all
values from PLC memory. Operator can also give setting values and control
commands from WOIS, which are then automatically transferred to PLC, which
operates according to the given setting values and control commands.

The PLC-system consists of one Genset PLC for each engine and one Common PLC.
Each PLC includes one CPU, which controls the process. The system is connected to
the monitoring system by Modbus Plus line.

Picture 1 Typical PLC configuration

Typical PLC system configuration is shown in picture 1. The exact projectwise

configuration depends on the amount of engines, IOs, communication methods and
control requirements. Exact configuration can be seen in appendix 3.1 (PLC SYSTEM
LAYOUT).

1.1 Hardware overview

Power supply module CPS 511 00 or CPS 524 00 feeds the power to all IO cards
using the backplane. The type of the module depends on the power consumption of
the modules. This module may not be disconnected from the backplane while the
power is on.

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CPU 434 12 contains the actual PLC program. It performs all the controls using other
cards to collect and control the I/O. It contains two modbus ports for external serial
communication and one Modbus Plus port for communication to WOIS and to other
PLCs. CPU contains battery to keep the software while power supply is not available.
Modbus Plus node number is located at the bottom of the card. This module may not
be disconnected or connected while the power is on.

Remote IO is collected to CPU using coaxial cable and modules CRP 931 00 and CRA
931 00. CRP 931 00 is located in the main rack and CRA 931 00 beside the I/O. Every
remote IO rack has one CRA 931 00 card. Every CRA 931 00 must have unique
predefined address, which is located at the bottom of the card.

PLC system includes various IO cards. Digital inputs are collected using DDI 353 00
for digital inputs. Digital outputs are controlled using DDO 353 00. Both these digital
cards include leds to indicate the status of each channel. ATI 030 00 is used for
thermocouples, ARI 030 10 for Pt100 measurements and AVI 030 00 for current and
voltage measurements. Every channel in each analog card includes F led. When the
led is red, the measurement is in sensor fault situation. For replacing a card, see 10.6.

1.2 Genset PLC

Genset PLC-system controls all the operations and collects all I/Os of one engine.
Typical operations for Genset PLC are starting and stopping of the engine, active and
reactive power control, shutdowns and trippings.

The Genset PLC consists of one rack in CFC0*1 panel and two (or three) racks in
CFE0*1 panel. The exact projectwise configuration depends on the available IOs,
communications and control requirements. Exact projectwise configuration is shown in
appendix 3.3 (GENSET PLC SYSTEM).

Power Monitoring Unit (PMU) and Numerical Generator Protective Relay (REM 543)
are connected to the modbus port of the CPU.

If more than one engine is included, their configuration is equal to configuration of

engine number 1.

1.3 Common PLC

Common PLC-system controls all the operations and collects all I/Os which are
common for the power plant. Typical operations of Common PLC are control of
grounding breakers and plant mode active power setpoint calculations.

Typical common PLC consists of one rack in CFA901 panel. The exact projectwise
configuration depends on the available IOs, communications and control requirements.
It is also possible to extend the amount of I/Os using the remote I/O cards (see Genset

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PLC). Exact projectwise configuration is shown in appendix 3.2 (COMMON PLC

SYSTEM).

1.4 Communication
All the PLCs and the WOIS stations are interconnected with the Modbus Plus line. The
WOIS station reads measurement values from PLCs all the time. Whenever
necessary, WOIS writes setpoints to PLCs. Whenever alarm occurs, PLC-system
sends it to WOIS.

Modbus Plus communication bus has been connected to WISE PC because of the
application and executive loader. See section 11 for details.
Common PLC is connected to the extended network via Ethernet switch.

Every node in Modbus Plus line must have a unique line address. The WOIS station
has Modbus Plus address 21, Common PLC has address 15. The first Genset PLC
has address 1, the second Genset has address 2, etc. Modbus Plus addresses must
be set properly even if for any reason the Modbus Plus would not be used at all.

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2. Starting sequence

2.1 Starting the engine

2.1.1 Starting conditions

The starting is only possible if all of the starting conditions are valid. If any of these
conditions is not valid, the start command will not be accepted. The starting conditions
are listed below:

• All emergency stops are inactive (Plant, Engine and Control room)
• Engine shutdown alarm is inactive
• Breaker trip alarm is inactive
• MCB is not open in AVR circuit
• Breaker conditions (Circuit breaker, earthing switch and disconnector are in
their right positions)
• Engine is not running
• Stop order and autostop are inactive
• Starting failure alarm is inactive
• Turning gear is not engaged
• Starting air pressure is > 18 bar
• Lube oil inlet pressure is > 0,5 bar
• Fuel oil inlet pressure is > 2,0 bar
• HT-water outlet temperature is > 50 °C
• Turbo A and B lube oil inlet pressure> 0.6 bar
• Local control switch blocking inactive
• Control air pressure > 15 bar
• Fuel flushing inactive
• Prelubrication pump running > 3 min
• Local control panel stop button ok

2.1.2 Starting of the 38 engine

The engine can be started either from M1 unit, from local panel or from WOIS operator
station. When the start command is given and all starting conditions are valid, the
PLC-system starts the engine by opening the starting air valve. Start command can be
aborted by pushing stop button.

If any other auxiliary devices (pump etc.) are needed, they will also be started after the
start command.

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2.1.3 Starting failure

If engine is not running 30 seconds after start command, start will be aborted and
alarm Start failure will be generated. This alarm remains active for 30 seconds, during
which new start is not possible.

If engine is running (rpm>300) during start and start failure occurs, stop solenoid will
be activated for 60 seconds. If engine does not reach the run status (rpm>300), stop
solenoid is not activated.

2.2 Synchronizing

2.2.1 Synchronizing in AUTO mode

When the engine has been running and the generator voltage has been on for approx.
10 seconds and AUTO has been selected as control mode, the PLC-system gives a
synchronization order to the synchronizing device.

At any time after the 10 second period while running in AUTO mode, the synchronizing
can be initiated by turning the Synchronizing select button or by giving Engine Start
command.

2.2.2 Synchronizing in MANUAL mode

When the engine is started in MANUAL mode, the engine stays in the idle running
state until the synchronizing is started either by turning the Synchronizing select switch
or by turning the engine control mode switch from MANUAL to AUTO mode for the first
time after the start command.

2.2.3 Synchronizing conditions

The PLC also checks the synchronizing conditions both in AUTO and in MANUAL
mode. These synchronizing conditions are:
• Engine is running
• Generator voltage is on
• Excitation is on
• Generator breaker is open
• Truck is in service position
• Breaker trip alarm is inactive and breaker trip circuit has been acknowledged.
• Busbar voltage is on
• No other synchronizing is active

If any of these conditions is not valid when the synchronizing should start, the
synchronizing will not be initiated. After removing the fault, the operator has the
possibility to reinitiate the synchronizing by Engine Start command (if in AUTO mode)
or by Synchronizing select switch.

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If the busbar is not alive, synchronizing is not possible. In this case the generator
breaker can be closed using Breaker close button in M1 control unit.

Stop command aborts synchronizing and also stops the engine.

2.2.4 Synchronizer position

Regardless of the position of the synchronizer in the CFA901 panel (AUTO or

MANUAL) the synchronizing will start as described above. If the synchronizer is in 0
position, no synchronizing can be initiated.

If the synchronizer is in AUTO mode, the synchronizing will be completely automatic. If

the synchronizer is in MANUAL mode, the synchronizing can be executed manually by
the operator. Another possibility is to turn the selector switch to AUTO mode. The
synchronizing will be aborted because the switch must go through 0, so the operator
must reinitiate synchronizing by giving Engine Start command or by turning
Syncronizing Select switch.

If the synchronizing does not succeed in predefined time (about 1 minute),

synchronizing failure alarm will be generated and the synchronizing will be aborted.

If the engine is running with breaker open more than 5 minutes, alarm will be
generated.

If PLC gives synchronizing command to digital output card but the synchronizing circuit
does not become active, operator gets alarm Synchronizing not activated.

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2.3 Running modes

2.3.1 KW control (Parallel with grid)

In AUTO control mode after the generator breaker is closed, the WOODWARD 723
controller increases the active power slowly to the set value which is given from the
WOIS station via the Genset PLC. If the set value is below 1000 kW (default value)
during synchronizing, it is set to 1000 kW.

When the setpoint has been reached, WOODWARD 723 keeps the desired active
power. Operator has the possibility to change the setpoint from the WOIS station.

In MANUAL control mode and when KW/Isoch. engine control is selected the
WOODWARD 723 controller is controlling the active power according to the pulses.
These pulses must be given by the operator using fuel increase / fuel decrease
switches in M1 control unit.

2.3.2 Droop control (Parallel with grid or island mode)

In MANUAL control mode and when Speed droop engine control is selected the
WOODWARD 723 is in speed droop mode. The engine output power will be according
to the consumed load. The speed reference (frequency) can now be adjusted (if
possible) by using fuel increase / decrease switches in M1 control unit.

2.3.3 Isochronous control (Island mode)

When the AUTO control mode or KW/Isoch. engine control is selected the
WOODWARD 723 is in isochronous load sharing mode. In isochronous mode the
engine output power will be according to the consumed load, so that the frequency is
stable. The load is also shared equally between running units.

2.4 Unloading and stopping

2.4.1 Unloading

When the engine is operating in kW or isochronous running mode, the stop command
gives an unloading order to the WOODWARD 723 conroller. If the engine is operating
in kW running mode and the AUTO control mode is selected, also the autostop
command gives an unloading order to the WOODWARD 723 conroller.

However if autostop occurs in any other running condition, the unload command is not
executed. See section 8 Engine autostop.

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If the engine is running in droop mode, operator must reduce the load manually (if
possible) and then open breaker from M1 control unit. Giving stop command does not
cause unloading.

The unloading procedure can be interrupted by giving a new start command. If the
unloading procedure is aborted, engine will either remain so (in kW running mode) or
return back to normal operation (in isochronous running mode).

However if the reason for unloading the engine was caused by the autostop command,
the interrupting of the unloading procedure is not possible.

When the unloading is complete, the WOODWARD 723 gives the open order to the
generator breaker. The engine will be stopped after 30 s cooling run.

2.4.2 Stopping

When the generator breaker is opened the engine is automatically stopped after 30 s
cooling run. If the stop button is pushed during the cooling run, the engine is stopped
immediately. During the cooling run, the stopping sequence can be interrupted either
by giving start command in MANUAL mode (the engine stays in the idle running state)
or by turning the synchronizing start button or by giving the start command in AUTO
mode (the engine is resynchronizied). The resynchronizing can also be done by turning
the engine control mode switch from MANUAL to AUTO mode for the first time after
the generator breaker has been opened.

When the engine has stopped, the engine stop order (stop solenoid) is active for 1
minute. During this period a new start order is not possible.

3. Active power control

When operating parallel with grid in AUTO or MANUAL control mode the Genset active
power is controlled by the Genset PLC-system. In the AUTO control mode the remote
PLC-system located in the CFE0*1 panel, feeds an 4-20 mA analogue signal, equal to
the set value from the WOIS station, to the WOODWARD 723 controller.
The set value is given to the controller when the following conditions are valid,
otherwise the set value is set to 0 kW:

• Engine is in AUTO control mode

• Generator breaker is closed
• Generator voltage is on
• Engine is running
• Unloading is not active

When operating parallel with grid in MANUAL control mode PLC-system controls the
maximum allowed active power and transfers the Fuel increase / Fuel decrease
switches to WOODWARD 723 controller.

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When operating in island mode, WOODWARD 723 controller controls the active power
according to the selected run mode and according to the Fuel increase / decrease
switches.

3.1 Derating measurements

When derating (automatic load reduction) is active, the maximum load to the Genset is
decreased according to ambient site conditions. The PLC-system calculates the
maximum allowed power in real time for each Genset. Exceeding this maximum
allowed power is not allowed.

The derating value varies between 0 to 100 % of the predefined maximum load to the
Genset. Derating is active in following conditions:

• HT cooling water temperature is < 70 °C

• Charge air cooler pinch point (Charge air temperature – LT water inlet to CAC)
is > 20 °C

The following conditions will derate the predefined max. active power in ISO
conditions:

Derating method 3:
• Air inlet temperature is either < 15 °C or > 35 °C
• Charge air coolant temperature is > 45 °C
• Site altitude is > 100 m
• Exhaust back pressure is > 500 mm H2O

If any of the derating measurements is out of range more than 10 seconds, the
maximum allowed power will be 85 % of rated electrical output.

Load reduction command also reduces the maximum allowed power value. See
section 7 Engine load reduction for more details.

3.2 Reducing the active power

Exceeding the maximum allowed power causes decreasing of the active power output
signal to WOODWARD 723 controller.

When operating parallel with grid in AUTO control mode and if the requested active
power is above the maximum allowed power for any reason more than predefined time
(default value 10 seconds), the PLC-system generates derating alarm. The alarm
remains active as long as the requested active power is above the maximum allowed
power.

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If for any reason in any run mode the Genset active power is above the maximum
allowed power for 1 minute, alarm Maximum allowed power exceeded. Reduce load.
Shutdown in 5 minutes will be generated. Operator should take the necessary actions
to reduce the active power. If the active power is not reduced, shutdown will occur. If
the active power is reduced enough, alarm will disappear and event Load ok,
shutdown cancelled will be generated.

4. Reactive power control (Cos phi control)

When the engine is running parallel with grid in AUTO control mode the PLC-system
controls the reactive power (power factor) by giving mA signal to Unitroll AVR
according to the set value given from the WOIS station. In MANUAL control mode the
cos phi is controlled manually from the M1 control unit. The PLC-system feeds
increase or decrease pulses to the AVR in order to increase or decrease the cos phi
value.

In island mode the control is deactivated.

5. Grid synchronizing

When synchronizing grid breaker every engine, which is running in island mode, must
be turned from isochronous mode to droop mode before engines are able to receive
synchronizer control pulses. PLC checks which engines are running in island mode
and forces them to droop mode.

Forcing to droop is made with one by one with small delays (default value 2 seconds /
engine). If 4 engines are forced to droop, the total procedure will take 10 seconds.

When all island mode engines are in droop mode, the synchronizing will be activated.
When synchronizing is complete, engines will be returned to previous state.

6. Generator breaker trip and engine shutdown

6.1 Generator breaker trip
When the generator breaker trip occurs, the PLC-system automatically stops the
engine after 2 minutes cooling run. Breaker trip alarm remains active until it is resetted
from the M1-unit by pushing Breaker trip reset button. Resetting is possible only after
all breaker trip alarms have been removed.

During the cooling run and after the breaker trip alarm has disappeared, it is possible
to interrupt the stopping sequence the same way as it has been explained in section
2.4.2.

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The PLC is generating a trip signal in the following cases:

• REM543 overcurrent I> TRIP

• REM543 Shortcircuit I>> TRIP
• REM543 Overvoltage U> TRIP
• REM543 Overvoltage U>> TRIP
• REM543 Reverse power P< TRIP
• REM543 Underreactance X< TRIP
• REM543 Earth fault U0> TRIP
• REM543 Earth fault U0>> TRIP
• REM543 Earth fault I01> TRIP
• REM543 Earth fault I01>> TRIP
• REM543 Over excitation U/f> TRIP
• REM543 Earth fault I02> TRIP
• REM543 Earth fault I02>> TRIP

Excitation fault is generated when excitation is on but the voltage disappears from
generator voltage supervision relay for 5 seconds.

6.2 Engine shutdown

The PLC is generating a shutdown signal if any of the emergency buttons is pushed or
when the following measurements exceeds or goes below shutdown limits:

• Cylinder average Exhaust Gas temperature is greater or equal to 550 °C for longer
than 100 seconds.

• Cylinder liner temperature is greater or equal to 155 °C for longer than 2 seconds.

• Main bearing temperature is greater or equal to 120 °C for longer than 2 seconds.

• Generator bearing temperature is greater or equal to 100 °C for longer than 2

seconds.

• Crankcase pressure is greater or equal to 20 mbar for longer than 5 seconds.

• Lube oil inlet pressure is less or equal to 2,5 bar for longer than 2 seconds.
• HT-water inlet pressure is less or equal than 1,5 bar for longer than 2 seconds.
• LT-water inlet pressure is less or equal than 1,5 bar for longer than 2 seconds.

• Lube oil inlet pressure low (Temperature switch).

• HT-water temperature high (Temperature switch).
• Charge air temperature high (Temperature switch).
• Oil mist high in crankcase (switch).

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• Power transformer oil temperature high (Temperature switch).

• Power transformer winding temperature high (Temperature switch).
• Power transformer gas pressure high (Pressure switch).
• Engine electrical overspeed 2 pcs. (From Despemes).
• Differential current protection trip
• Speed control common alarm
• Shutdown from autostop
• Exceeding max. allowed power caused shutdown

When the shutdown alarm appears, it remains active until it is resetted from the M1-
unit. Resetting is possible only after reason for shutdown alarm has been removed.

6.3 Detecting primary reason

PLC makes sure that operator can easily detect the first shutdown or tripping.
Whenever first shutdown or tripping occurs, it is allowed to go to WOIS alarm list
immediatelly. After the first shutdown or tripping is a predefined period (default 2
second), during which all other shutdowns and trippings are blocked. After this
predefined period all shutdowns and trippings are allowed to pass whenever they
occur.

This procedure makes sure that the first shutdown or tripping in WOIS alarm list is the
actual reason. All other possible shutdowns and trippings have most probably been
caused by this first reason.

If the breaker trip is caused by REM543, it is indicated in the alarm list with digital
alarm "Protection relay breaker trip". If this is the first reason for tripping, the PLC waits
for the actual reason from REM543 over the modbus serial link. The default value for
the waiting time is 5 seconds. When the actual reason arrives to PLC, it will be shown
as a next tripping alarm in the WOIS alarm list.

If shutdown reset or trip reset is given during the blocking of alarms, it will delayed until
the data blocking has been removed and all data has been transfered to PC.

If two alarms occur inside one PLC scan (about 30 ms), PLC can not detect which one
is the first. In these cases both of them will be shown in the alarm list with the same
timestamp.

7. Engine load reduction

When running parallel with grid in AUTO control mode, the load reduction will reduce
the engine´s actual power by 15 percents. However, the power is not allowed to go
under the minimum power limit (Approximately 30 % of the rated electrical output of
the engine).

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When running parallel with grid in MANUAL control mode or in island mode, the load
reduction is only alarm for the operator. The alarm text is:
Engine load too high, reduce load 15%. Shutdown danger.

Operator should take necessary actions to reduce the power. If operator does not
react, shutdown will occur according to the backup function of the measurement.
When the alarm disappears, event will occur:
Engine load ok, shutdown avoided.

The load reduction alarm is activated/deactivated in the following cases:

• The engine load reduction is activated if the Exhaust Gas temperature average value
for one cylinder is greater or equal to 550 °C for longer than 10 seconds. The load
reduction alarm is deactivated if the Exhaust Gas temperature average values for all
cylinders are below 550 °C for longer than 10 seconds. As a backup function shutdown
will occur if the Exhaust Gas temperature average value for one cylinder is greater or
equal to 550 °C for longer than 100 seconds

• The engine load reduction is activated if the HT-water outlet temperature is greater or
equal to 100 °C for longer than 10 seconds. The load reduction alarm is deactivated if
the HT-water outlet temperature is less than 100 °C for longer than 10 seconds. As a
backup function shutdown will occur if HT water outlet temp exceeds 105 for 2
seconds.

The actual load reduction is deactivated if the actual reason has been inactive for 2
minutes.

8. Engine autostop
Autostop alarm either unloads the engine, executes shutdown after predefined delay
or gives alarm to the operator. Operation depends on the selected run mode and on
the measurement which caused the autostop.

If generator breaker is open, any autostop will stop the engine immediatelly. The
engine can not be started (engine start blocked) if any of the autostops is active.

8.1 Parallel with grid in AUTO mode

When operating parallel with grid in AUTO control mode, engine autostop activates the
unloading sequence (see section 2.4.1), which unloads the engine and opens the
generator breaker. If the unloading has been caused by autostop, it can not be
cancelled even if the reason for autostop would have disappeared.

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If autostop is active, when the generator breaker opens, the engine will stop
immediatelly. If the autostop has disappered, the engine will run idle for 30 seconds.
During this cooling run period it is possible to interrupt the stopping sequence in the
same way as it has been explained in section 2.4.2.

8.2 Other run modes

If the autostop occurs in any other running condition when the generator breaker is
closed, the actions caused by autostop depend on the group the autostop belongs to.
The autostops are divided into following groups:

Measurements which cause shutdown after 15 minutes

Autostop will be activated if deviation of the average Exhaust Gas temperature

value for one cylinder from average of the whole engine Exhaust Gas temperature
is greater or equal to ± 90 °C (8 & 16 cylinder engines) or ± 70 °C (other engines)
and the condition is remaining true for longer than 300 seconds.

When autostop is activated, the PLC-system generates an alarm Engine misfiring.

Check fuel supply. Shutdown in 15 minutes.

If this alarm occurs, the operator should take the necessary actions to check the
fuel supply and avoid the shutdown. When the alarm disappears, the PLC
generates an event Shutdown cancelled.

Measurements which cause shutdown after 5 minutes

Autostop will be activated if generator winding temperature is greater or equal to

150 °C for longer than 15 seconds or charge air temperature is greater or equal to
75 for longer than 10 seconds.

When autostop is activated, the PLC-system generates an alarm Engine load too
high, reduce load 15%. Shutdown in 5 minutes.

If this alarm occurs, the operator should take the necessary actions to reduce load
and avoid the shutdown. When the alarm disappears, the PLC generates an event
Engine load OK. Shutdown cancelled.

Measurements which cause shutdown after 5 minutes (no load reduction)

Autostop will be activated if lube oil inlet temperature is greater or equal to 85 °C

for longer than 2 seconds or oilmist detector autostop is active.

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When autostop is activated, the PLC-system generates an alarm Engine shutdown

in 5 minutes.

If this alarm occurs, the operator should take the necessary actions to return back
to normal situation and avoid the shutdown. When the alarm disappears, the PLC
generates an event Shutdown cancelled.

Measurements which only cause alarm (no shutdown is executed)

These measurements only cause an alarm. No shutdown is excecuted. Alarm will

be activated if starting / control air pressure is less or equal to 10 bar for longer
than 5 seconds.

9. Other controls
9.1 Controls of the Common PLC

9.1.1 HFO buffer tank filling valve control

Operator can adjust open and close setpoint from Wois between 50 and 90%
The HFO buffer tank filling valve open order signal is activated when there is a low oil
level in the HFO buffer tank (50% or adjusted value). The valve close order pulse is
activated if there is a high oil level in the HFO buffer tank (90% or adjusted value).

Either control will not be given if there is a sensor fault in the level measurement.

9.1.2 LFO tansfer pump control

Operator can adjust open and close setpoint from Wois between 50 and 90%
The LFO transfer pump startorder signal is activated when there is a low oil level in the
LFO day tank (50% or adjusted value). The pump stop order pulse is activated if there
is a high oil level in the LFO day tank (90% or adjusted value).

Either control will not be given if there is a sensor fault in the level measurement.

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9.2 Controls of the Genset PLC

9.2.1 Radiator control

Genset PLC controls the fans of radiator cells, used for cooling the engine. PLC starts
and stops radiator cells depending on the temperature of the HT outlet temperature.
Starting of the radiator cells is circulated. Every time the engine is started, next cell will
start first.

9.2.2 Ventilation fans control

Genset PLC puts the ventilation fans on when engine starts and keeps them running 5
minutes after engine stops. Fans can be turned on/off from WOIS screen when engine
is stopped, but PLC will in any case start and keep them running when engine runs no
matter what is selected from WOIS screen.

If the fan is not running when PLC control for it is on, alarm will be generated.

9.2.3 Prelube pump control

Prelube pump is started automatically, when engine is stopped and pump control is in
auto –mode. Pump will stop after engine running signal.

9.2.4 Control of the main fuel valve

When fuel system flushing is selected from Wois, main fuel valve goes to LFO –
position automatically. Control goes off when quality of flushed fuel is ok.

9.2.5 Control of the booster pumps

Operator select from the Wois screen, which pump will start when engine is started.
This pump is then valid untill operator change it.

9.2.6 Booster module quick closing valve control

When emergency stop occures, quick closing valve is closed and fuel flow to engine is
stopped.

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10. Troubleshooting

10.1 Battery low charge alarm

When the Battery low charge alarm is activated in the WOIS station, the memory
backup battery in the CPU has to be changed. This same information can be seen
from the red Batt low LED on the control processor. Battery specification according to
Modicon is: 10 years w/ 0.5% loss of capacity each year.

During the battery change DO NOT SWITCH THE POWER OFF !!. Otherwise the
hardware configuration and PLC program will be lost. In this case the restart of the
system requires complete PLC programming software or Application and executive
loader (see section 11).

10.2 Program not running

Every CPU must have green RUN led on all the time. If this led is not running, the CPU
is not operating at all. See seciotn 11 for recommended operation procedure.

10.3 VAMP260 or REM543 communication failure alarm

If communication failure alarm to VAMP260 or REM543 occurs, operator can only
check that the device is operating properly and that the communication cables has
been properly connected to VEA modules and to actual VAMP devices.

The operation of the communication can be seen from the blinking yellow Comm led in
front panel of the VAMP device. Data is requested by the PLC and the led blinks
always when device answers to the query. In normal operation, the led should blink
about once in one second.

10.4 Communication failure between PLCs

Communication between PLCs has been done with both Modbus Plus and Ethernet. If
both these communication methods fail, alarm is generated to operator.

Communication is very critical for the system. Enginewise PLCs will run properly as
standalone, but they should get valid data from Common PLC over the communication
buses all the time. Common PLC includes for example synchronizer and breaker
status informations.

If communication alarm occurs, the fault is most probably in the cable connections.

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If Modbus Plus network includes two nodes with same address, that communication
fails. If new node has recently been added to Modbus Plus network, the addresses
should be checked.

It is also possible to check that all PLCs are talking over Modbus Plus. In each CPU
the led Modbus + should blink 6 times / second. If it is blinking very slowly (once a
second) the Modbus Plus connection is not working.

If Ethernet communication fails, reason may also be duplicate IP addresses in the

network.

10.5 Sensor fault

Sensor faults are indicated in the WOIS alarm list and in the card with red F indication.
If sensor fault occurs, check the hardware connection. Usually the problem is for
example loose connection.

Of course it is also possible that one channel is broken in the card. It is possible to
check this by trying another module. See section Card failures.

10.6 Card failures

If any of the cards fail, alarm is generated in the WOIS. The alarm text is: Module fault
rack x slot y where x and y identify the exact location of the card. If the module is
secured properly, it is most probably faulty.

Before ordering a new module, it is recommended to test the hardware connection by

replacing the module with another same kind of module. The PLC system usually
includes same modules in different places, so it possible to borrow module from
another place.

All I/O (DDI 030 00, DDO 030 00, AVI 030 00, ATI 030 00, ARI 030 00, ACO 020 00)
modules may be replaced while the power supply is connected to the PLC. However if
the engine is running while disconnecting module and it includes any critical I/O,
engine will shutdown or breaker will trip. Therefore it is strongly recommended to stop
the engine before disconnecting modules.

While replacing any module, it is recommended to check also the bottom of the
module. Some modules (CPU, NOM, CRA) include rotary switch, which must be preset
in the new module exactly the way. Also some modules (CPU, NOM) include dip
switches in the front of the module. These must also be preset accordingly before
inserting the module into the rack or before connecting the power supply.

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10.7 Replacing CPU

Replacing the CPU requires complete PLC programming software or Application and
executive loader (see section 11). Both correct executive and latest application must
be downloaded to CPU. Also the Modbus Plus address must be set with the rotary
switch and the dip switches must be adjusted according to the old module.

11. Application and executive loader

11.1 General
Always, when the power supply is on, all CPUs should have green RUN light on. If the
light is not active for any reason, PLC is not running and it must restarted. For this
purpose two separate tools have been included to WISE PC. These tools are
Application loader and ExecLoader. Program monitoring or modifications are not
possible with these tools. WISE computer also includes Modbus Plus communication
card to enable these programs to communicate to PLC. See WISE manual for detailed
information how to start these programs.

Application includes the actual PLC configuration and projectwise PLC code. Executive
is the operating system of the PLC.

Operation of these tools has been explained in sections 11.2 – 11.6. Basic principle is
that operator has to go step by step by executing first section 11.2, then 11.3 and so
on. Whenever the CPU actually starts, further actions are not needed.

If at any stage error code is shown in programming PC, please inform it to technical
support because it helps to locate the actual reason for the problem.

This manual is valid for single CPU systems only, hot-standby systems can not be
downloaded according to these instructions.

11.2 Power OFF and ON

After CPU has stopped, first step is to turn the CPU power supply OFF and ON again
after few seconds. See electrical drawings to locate the correct MCB.

If the CPU starts, no further actions are needed.

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11.3 Key
If power OFF/ON fails, use the key in front of the CPU (not available in all CPU
models). Find the correct key and insert it to the keyhole. Make sure that the power
supply is on and turn the key to the leftmost position and after few seconds to the
rightmost position. PLC should start.

Never leave the key to the middle position, this is the memory protection position and it
will cause a lot of problems to the PLC program.

If the CPU starts, no further actions are needed.

11.4 Connect to PLC and start the CPU

It is possible to start the PLC also by using the application loader tool. Start Application
loader program according to WISE manual instructions.

11.4.1 Connect to PLC

Select Online / Connect, after which new window opens. In this window, the protocol
type must be Modbus Plus and access level Change configuration.

The most critical selection is the selection List of nodes on Modbus Plus network. User
must know the exact Modbus Plus address of the faulty PLC. If the address is not
known, wrong PLCs maybe connected with unpredictable concequencies. Basic
principle is that engine number 1 has Modbus Plus address 1, engine number 2 has
Modbus Plus address 2 etc. Common PLC has usually address 15. All numbers above
20 are computers.

Locate the correct Modbus Plus address and select OK. If the correct address is not
visible in the list, try to change the Device number Port 0 to Port 1. Usually Port 0 is the
correct selection. After doing this, you are connected to CPU.

11.4.2 Start controller

Select Online / Online control panel (or push Ctrl P). A new window appears, where
user should select Start controller. After the confirmation question, PLC program
should start. Note that selection Start controller is visible only if the CPU actually is in
stopped mode. If Stop controller is visible, the PLC is running, which means that you
may have connected to wrong PLC.

Regardless of the result, close the window and select Online / Disconnect. Then close
the application loader tool by selecting File / Exit.

If the CPU starts, no further actions are needed.

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11.5 Download application

If all above mentioned operations fail, it means that PLC has lost the entire application
and it must be downloaded again.

While downloading the application, it is very important that the WISE PC includes
latest application. If after download, previously fixed problems occur, most probably the
application was not the latest one. Then only possibility is to contact technical support.

Start Application loader tool. Select File / open and find the path c:\Aploader\plc_app
(default path). Then locate the program, which you want to download. Enginewise
program is as a default called ENGINE1 for engine 1 etc. Common program is usually
COMMON. Open the correct program. Note that if only modbus plus is used as a
communication bus, as default all engines use the same program called ENGINE.
However if ethernet is used in any way, a separate program must be available for each
engine.

Opening the program takes a while, however no windows will be opened. After that
connect to PLC exactly as described in section 11.4.1. Most probably you will get
notification Controller´s configuration not equal to configuration database. This is
normal because PLC does not have the configuration anymore, click OK.

To download the program, select Online / Download. In the new window, make sure
that marks Configuration and IEC program sections have been marked. No other
selections are allowed. Download starts with Download command. After a while
program asks: Download complete. Start controller? Answer YES.

If the CPU starts, no further actions are needed.

Regardless of the result, close the window and select Online / Disconnect. Then close
the application loader tool by selecting File / Exit.

11.6 Download PLC executive and application

In most difficult cases, nothing above mentioned methods is enough. Then the only
possible solution is to download also the executive (operating system) to PLC.

Open ExecLoader. ExecLoader opens with welcome screen. Select Next.

Step 1: Select protocol

Make sure that the Communication protocol is Modbus Plus, then select Next.

Step 2: Select target device

Bridge selection must be OFF and Device type must be PLC.

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Push Rescan button to locate all Modbus Plus nodes. Available nodes appear to the
column Nodes found. If correct node is not found, try to change Adapter 0 to Adapter
1. However usually Adapter 0 is the correct selection.

See section 11.4.1 for identifying the correct Modbus Plus node. After locating the
correct node number, select it by clicking and select Next.

Step 3: Select operation

Select the Operation Transfer EXEC to Device.

Use the Browse button to locate correct executive file. Files are located in
c:\Aploader\dat directory (default). Correct file depends on the CPU type. For CPU 434
12A the correct file is Q5rv104d.bin (or newer). For all other CPU types, contact
technical support. After selecting the correct file, click Next.

Step 4: Select operation

Confirmation screen where it is possible to compare the executive in PLC and the
executive you have selected. If the files are the same (Model number and Description),
select Next. Otherwise check Step 3 selection.

Tip: If you are unsure, which executive to download, use this screen to verify that you
are about to download the same executive, which already is in the PLC. If necessary,
return to previous screen (Back) to change your selections.

Step 5: Initiate transfer

Select transfer and if doubtful, check the selections you have made.

Step 6: Actual transfer

After selecting transfer, you get a warning message: Current control application will be
deleted…select YES. Transfer begins and takes several minutes.

When the transfer is complete, reboot the PLC (power OFF and ON). Select close
few times to exit the program.

Then download the application again exactly as described in the section 11.5.

PLC should start.

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