Unigen Plus Technical Documentation
Unigen Plus Technical Documentation
UNIGEN PLUS
Technical documentation
CRE Technology believes that all information provided herein is correct and reliable and reserves the right to
update at any time. CRE Technology does not assume any responsibility for its use. E & O E.
Technical documentation history
INFORMATION
You can download the most up-to-date version of this documentation and different other
documentations relating to CRE technology products on our Web site
http://www.cretechnology.com.
Each terminals of the industrial UNIGEN are also available on UNIGEN PLUS.
Chapter : Overview
Starting from firmware v2.00, UNIGEN modules are compatible with PC software CRE Config.
This software gives you the ability to communicate with your module using RS232 serial
communication. Serial COM port is placed under the front cover of UNIGEN modules.
UNIGEN modules can be installed without any computer, but you may want to use CRE Config
software to set advanced parameters or display internal measurements such as generating set voltages,
currents, active power and so on.
Chapter : Overview
For more information, please refer to the following documentation available on CRE technology Web site:
A70 Z1 9 0003: CRE Config user manual.
A51 Z1 9 0015: TCP-IP connection under Windows XP.
A51 Z0 9 0246: TCP-IP connection under Windows 7.
SYNC_OK output (terminals 34/35) permit the coupling of generators when all following conditions are
correct:
Voltage of generator and bus bar within a 15 - 130% window from nominal voltage (500V).
Voltage difference between generator and bus bar, < 10%.
Frequency of generator and bus bar within a 30 - 130% window from nominal frequency.
Phase Angle difference between generator and bus bar. <+/- 10°.
Frequency difference between generator and bus bar, < 0.01Hz.
Phase sequence correct.
Switch SW5 allows or not to close the generator breaker even if SYNC_IN logical input is not active.
Switch SW6 allows or not to close the generator breaker on a dead bus bar.
Table below describes the behaviour of SYNC_OK relay depending on the actual setup of your module and
according to voltage measurements on generator and bus bar sides.
Chapter : Features
Inactive X OFF X X open
(not connected)
OFF ON X NOK open
Inactive X ON NO OK closed
(not connected)
ON ON YES NOK closed
ON ON NO NOK open
Table 1: SYNC_OK logic table
X = Do not care.
NOTE:
Since firmware v1.28, SYNC_IN input is taken into account only if both generator and Mains/Bus frequencies
are greater than a predefined percentage of nominal frequency. This percentage can be changed using
parameter E01226. It is factory set to 0% to help you check AVR and speed output range during commissioning,
but it may be useful to set it to a higher value (e.g. 80%) depending on your use of SYNC_IN input.
Since firmware v2.00, SYNC_OK output can be delayed according to parameter E01227. In this case, SYNC_OK
output is closed when all parameters described above are in the proper conditions during the delay set in
parameter E01227. Otherwise SYNC_OK is kept open.
After power on sequence on dead bus conditions, a minimal delay must elapse before SYNC_OK relay is
closed. This delay may be adjusted using parameter E01033 (Default value is 3.0s).
UNIGEN includes a reverse kW relay on terminals 9 and 10. This relay output closes when the kW of the
generator is below -5% of the nominal kW during more than 20 seconds.
The REV._kW red LED confirms the activation of the relay:
LED ON = contact closed.
LED OFF = contact open.
4.3 kW Indicator
UNIGEN has two analogue outputs for kW indicator on terminals 11, 12 and 13. These outputs allow the
display of active power (kW).
Outputs are between 0-5VDC, 0-20mA or 4-20mA depending on SW4 configuration. A multi-turn potentiometer
allows the calibration of the output to adapt it to your indicator.
Chapter : Features
4.4 Remote speed control input
UNIGEN includes a remote speed control input on terminals 14, 15 and 16. This input is provided for
connecting an external potentiometer (5kΩ). The mid-point of this potentiometer (5 turns for a 10 turns
potentiometer) will generate a 0V signal to the cursor input and will not generate any speed deviation.
Maximal speed deviation depends on the speed output adjustments. When it is adjusted for the
recommended range of +/- 3.00Hz, then the following rules apply:
+5V applied on cursor input will increase the speed of + 3.00Hz.
-5V applied on cursor input will decrease the speed of -3.00Hz.
This input can also be used as 0…5VDC for a master PLC control. In this case the nominal speed must be
adjusted when 2.5VDC are applied on the cursor input.
When DROOP input (terminal 4) is open and DIP-switch SW3 (plines/canbus) is set to select CAN bus (ON
position for UNIGEN PLUS), UNIGEN is in isochronous load sharing mode. The load setpoint will be calculated
via the CAN connection.
Up to 8 UNIGEN modules can be connected via CAN bus.
The CAN bus needs terminal resistors at each end of the bus. Switch SW1 (CAN bus termination resistor
OFF/120Ω) to ON position on the first and last UNIGEN modules connected to the physical CAN bus. SW1
should be switched OFF on all other UNIGEN modules.
4.1.1 Plug’n’play CAN protocol
As soon as several UNIGEN are connected together through CAN bus, they automatically choose a generator
number different from each other. They are able to share the load without any settings. If one UNIGEN
disappear from the CAN, it is no longer taken under account by the others, and they continue to share the load
isochronously.
The rules of the Plug’n’play CAN protocol are described below:
UNIGEN must receive information on the availability of the GE. (Input SET_UNAVAILABLE). If this
information is set to 0 then the UNIGEN will not participate to the negotiations.
A generator is considered as slave when the SLAVE INPUT is connected to 0V.
Chapter : Features
At least one UNIGEN must be configured as master (SLAVE INPUT not selected).
At power up, all UNIGEN connected to the CAN bus will be automatically attributed a set number (1, 2,
3...) according to the power supply sequence of the UNIGEN. If multiple units are powered ON at the
same time, then serial number will be used to attribute a different group number to each unit.
At power up, all UNIGEN are fully operational during 2 minutes (No stop negotiation), then the
automatic load/unload mode starts.
Note:
Plug’n’play can be inhibited if you want each unit to keep the same generating set number whatever the status
of other modules (powered ON or OFF). To do so, set parameter V01038 to 0 on all UNIGEN modules and select
a different generating set number to each module using parameter V02192. Do not forget to save parameters
in FLASH memory so the setup will be kept even if power supply is lost.
When DROOP input (terminal 4) is open and switch SW3 (plines/canbus) is on plines position (OFF), UNIGEN
PLUS is set to isochronous load sharing mode, it compares its power with the level of the paralleling lines and
generates an output signal to the speed governor to adjust its power.
3V
0V KW%
0% 100%
Parallel lines are compatible with other analogue sharing lines products on the market. This can be useful to
extend power plants with heterogeneous control units. Examples of such products are:
GENSYS/GENSYS 2.0 product range from CRE technology.
Barber Colman products (ex: DYN2-80109, Pow-R-Con…).
Woodward 2301A controller.
…
MICS® Process II
Carantec board
13 Parallel lines +
44 Parallel lines -
Figure 3: Connecting with Carantec boards
When DROOP (terminal 4) input is connected to 0 VDC, UNIGEN is in Super droop mode. In this mode the load
sharing is managed between 50.50Hz (0% load) and 50.00Hz (100% load).
Chapter : Features
For this specific droop, it is not needed to set precisely the engine speed, and any connections are required
between each UNIGEN, even the 0V.
kW and kVAR load sharing are managed with droop.
Freq
50.50Hz
50.00Hz KW%
0% 100%
The START_ON_LOAD_REQUEST relay output can be used to start and stop the slave generators depending on
the power plant load. START_ON_LOAD_REQUEST green LED confirms the activation of the relay:
LED ON = contact is closed.
LED OFF = contact is open.
Figure below gives an example of power plant with three generating sets. Two of them (UNIGEN with
SLAVE_INPUT connected to 0V) can request to start or stop their engine depending on the global load of the
power plant.
Auto start
module
Auto start
module
Chapter : Features
Auto start
module
CAUTION:
If UNIGEN is running and on the bus bar, as soon as SET_UNAVAILABLE
input is closed the TRIP_OUT relay is activated (closed) to open the
breaker of the generator.
Load threshold
Unload threshold
Power plant kW
Chapter : Features
BREAKER_IN
TRIP_OUT
START_ON_LOAD_REQUEST
Note: at start up, START_ON_LOAD_REQUEST relay is closed. All generators are started because it is impossible
to know the level of load before start.
Ramp sequences:
The first generator on the bus bars takes immediately the load with no ramp.
kW
Power plant power
100%
60%
TRIP_OUT relay (terminals 7 and 8) is used to open the breaker once the unload ramp is finished. The relay is
closed when the kW of the generator which is unloading reaches 5% of the nominal kW.
TRIP_OUT green LED is lit to confirms the activation of the relay:
LED ON = contact closed.
LED OFF = contact open.
The Load/Unload ramps are managed by the UNLOAD input (terminal 6):
UNLOAD input disconnected = when the breaker closes, the load ramp starts immediately.
UNLOAD input connected to 0V = the generator starts an unload ramp.
Chapter : Features
4.4 COMMAND MODE (UNIGEN PLUS)
(CW) +5V
(CCW) 0V
or not
kW (%)
connected
5% 110%
COMMAND mode is described in the second schematic shown on MAINS PARALLELED chapter.
Chapter : Features
3V
0V KW%
0% 100%
COMMAND mode and MAINS PARALLELED active power behaviour are described in the schematic below:
Generator load
Load setpoint::
Command mode load=kW sepoint input,
Mains paralleld load=paralleling lines input.
Low limit
Unload Low
request limit
Active power set point behaviour in different mode is described in the following table:
Mode kW/Speed
PARALLELED
COMMAND
management
BREAKER
UNLOAD
DROOP
SW3
MAINS
MODE
according to
IN
Chapter : Features
open closed closed X X X Droop Frequency
closed closed open X X X Unload Ramp time pot.
open closed open open open ON Load sharing CAN bus
open closed open open open OFF Load sharing Parallel lines
open closed open X closed X Fixed kW kW set point
Paralleled
open closed open closed open X Parallel lines
with Mains
Table 2: kW/Speed management
Figure below shows the speed and parallel lines connections that can be done between UNIGEN PLUS and a
GCR module from CRE technology in order to parallel a power plant with the Mains.
All the logical and analogue input/output values and all the other parameters which appear in the UNIGEN
PLUS menus can be read by the serial port RS485 terminals 49A and 50B (2 wires). UNIGEN PLUS behaves as a
MODBUS slave device.
Chapter : Features
If your UNIGEN PLUS is located at one end of the RS485 network, then you should activate the internal 120Ω
termination resistor by switching SW8 (Modbus OFF/120Ω) to ON position.
Support of MODBUS RTU by the UNIGEN PLUS is performed using the following parameters:
Communication speed: 4800, 9600 and 19200 (default: 19200).
Number of bits by character: 8.
Number of parity bits: 0.
Number of stop bits: 1.
Supported function: 04 (analogue reading) and 03 (registers reading) and 06 (registers writing).
The RTU address of the variables is the same than their number plus 1, converted in hexadecimal.
Example:
Variable E00110 (Mains breaker status) has RTU address 006Fh (Decimal 111). See file A51Z090030 for the
whole list of existing registers.
Chapter : Features
CRC16 (MSB) --
CRC16 (LSB) --
Changing Modbus RTU slave address (Parameter E01215) and communication speed (Parameter E01216) of
the UNIGEN PLUS:
Enter desired value for the specific parameterand press Save button.
Go to menu System / Save all variables
Click on "Flash it!” button.
Disconnect UNIGEN, switch power off and then switch it on for new settings to take effect.
UNIGEN modules include the following adjustments for calibration and settings:
Chapter : Settings
None Multi turn potentiometer (-10 to +10 VDC).
Offset adjustment of the voltage control output
Also see dedicated commissioning chapter.
6h
Single-turn potentiometer (0 to 10VDC).
Span adjustment of the voltage control output
Also see dedicated commissioning chapter.
Table 3: Potentiometers
SW5: synchronization.
OFF: SYNC_OK relay closes only when synchronisation conditions are OK and
SYNC_IN input is active (connected to the 0VDC).
ON: SYNC_OK relay closes when synchronisation conditions are OK whatever
the value of SYNC_IN input.
Also see SYNCH CHECK RELAY dedicated chapter.
Chapter : Settings
OFF: external SPEED_SET potentiometer is always active.
ON: external SPEED_SET potentiometer is not active when the generator
breaker is closed.
Also see REMOTE SPEED CONTROL dedicated chapter.
LED Description
Chapter : Display
This LED is ON when SYNC_OK relay is closed.
This LED blinks when load sharing is done through CAN bus.
This LED blinks according to the number of UNIGEN modules
detected in the CAN bus.
Table 5: LED description
Recommended
Terminal Name wires Description
(mm² / AWG)
9 to 40 VDC power supply, 10 W. Protected against
1 POWER SUPPLY + reverse connection. Fuse: 5A / 40VDC.
2.5 / 13
2 POWER SUPPLY- Note: terminal 2 must be connected to the 0V
terminal of the speed governor with a 4 mm² wire.
Activates automatic synchronization of the generator
3 SYNC IN 1 / 17 to the bus bar.
See SW5 and SW6 configuration.
Chapter : Terminals
13/12) analogue output proportional to the generator
active power.
13 +Power monitor 0.25 / 23
(0…20mA)
14 SPEED SET CW +5V 5kΩ potentiometer input or +/-5VDC between terminal
15 SPEED SET cursor 0.25 / 23 * 2 (-) and 15 (+). Use a shielded wire.
16 SPEED SET CCW -5V Manual remote control of generator speed.
+/-10 VDC analogue output. Use a shielded wire.
17 Generator OUT Engine speed control output compatible with most
0.25 / 23 * speed governors on the market.
18 Generator REF See dedicated commissioning chapter and SW2
(from speed governor) configuration.
19 Shield 0.25 / 23 * Connect the shield of the analogue signals.
Isolated analogue output +/-10VDC.
20 AVR OUT (+)
0.5 / 20 * Controls alternator voltage. Offset and gain
21 AVR OUT (-)
potentiometers.
22 Generator I1+
AC current inputs from generator.
23 Generator I1-
0 to 5A inputs (1VA).
24 Generator I2+
2.5 / 13 Withstands up to 15A during 10s.
25 Generator I2-
Nominal current input must be as close as possible to
26 Generator I3+
5A for maximum accuracy.
27 Generator I3-
Chapter : Terminals
Isolated input. Load sharing through CAN bus
46 CANBUS+ communication.
2.5 / 13*
47 CANBUS- Used when SW3 is ON for UNIGEN PLUS.
See also SW1 configuration.
48 SHIELD 0.25 / 23 * Connect shields of analogue signals.
49 MODBUS A 19200 bps RS485 Modbus RTU slave.
2.5 / 13 *
50 MODBUS B Also see SW8 configuration.
51 Bus bar L1 AC voltage measurement inputs from bus bar.
52 Bus bar L2 100 to 500 VAC (Line to line), 50/60 Hz.
1.5 / 16
53 Bus bar L3 Use 100 mA / 600 VAC fuses.
54 Bus bar neutral Note: neutral connection is optional.
RS232 to PC or Connection via CRE Config software.
COM1 Female DB9
modem Use a straight 9 wires cable.
Table 6: Terminals of the module
L1
L2
L3
N
Auto
100 - 480 V
Mains
Failure
F
F
F
-Alim
(optional) Bus N 54
Bus L1 51
Bus L2 52
Bus L3 53
Mains paralleled 38
34 Synch OK
Breaker NO Start on load
35 32
-Alim control request
9 NO 33
Rev. kW
10 NO
Modbus A 49
7 Trip out
RS485
Modbus B 50
8 NO
S1 48
P1 22 Gen I1+
25 Gen I2-
P2 S2
Parallel lines high 44 CRE
P1 S1
24 Gen I2+
45
UNIGEN
27 Gen I3- Parallel lines low
P2 S2 Barber Colman
P1 S1
PowRcon
26 Gen I3+
L1
N
100 - 480 V
31 Gen N (opt) UNIGEN Barber Colman
DYN2-80109
F 28 Gen L1
L3
L2 F
F
29
30
Gen L2
Gen L3
PLUS Woodward
2301A
Surge 21 AVR out -
diverter
20 AVR out +
G AVR
19
Chapter : Terminals
governor 17 Speed out kW setpoint 41
15 Speed setpoint
5k potentiometer
Set unavailable
11 kW out +5V
Power supply +
Power supply -
Power monitor
Slave input
0...5V or 12 kW out 0 or
Unload
Sync in
Droop
0...20mA 0...5V
5k potentiometer
13 kW out 20mA
1 2 3 4 6 36 37 39
or
+/-5V Chassis 5A
F
isolated from
power supply +Alim -Alim
+ -
From speed
Battery
governor (4 mm²)
Due to the big sensitivity of Cummins EFC speed input, wiring should be applied as shown below. This allows a
higher voltage span on UNIGEN speed output.
Speed governor
CUMMINS EFC
2
8
15k
1.5k
9
2
11
12
Chapter : Terminals
7.5 Connection to a Leroy Somer voltage regulator
Most Leroy Somer AVR modules feature an input for an external potentiometer for voltage control. Figure
below shows the example of an R448 AVR connection.
R438 / R448 / R449
Leroy Somer
(Ext. Pot.)
T.I. ST4
Power supply: 9 to 40VDC, <1A with 12 VDC and <500mA with 24VDC.
AC voltage inputs: 100 to 500VAC, 100mA max. The neutral wire can be connected or not.
AC currents inputs: 0 to 5A, 1VA. Each input is isolated from the other ones.
Possible over-current: 15A during 10s.
Frequency measurement: 45 to 70 Hz – 15 VAC minimum between neutral and line.
Digital inputs: Normally open, not isolated, internal pull up of 10kΩ. Connect to 0V to activate.
Relay outputs: 5A, 230VAC max.
Remote speed control input: 5kΩ potentiometer or ±5VDC.
Remote kW control input for COMMAND mode: potentiometer (5kΩ) or 0…+5VDC.
kW monitor output (0…5VDC or 0…20mA/4-20mA): 300Ω maximum load on the 0…20mA or
4…20mA output. 1kΩ minimum load on the 0…+5VDC output.
Speed bias output: The frequency control is made by the adjustable 0…10VDC output. Adjust
using OFFSET and GAIN potentiometers.
Voltage bias output: The voltage control is done via the AVR. The output is a ±10V. Adjust using
OFFSET and GAIN potentiometers.
Terminals: with screws, 2.5 mm2.
Chapter : Terminals
8.1 Caution
8.1.1 Grounding:
The grounding of the chassis of UNIGEN must be done with the M5 screw. Use a 4mm² wire to connect to
earth, this cable should be as short as possible.
The cables with high voltage (400VAC) and/or high current (5A) must be separated from the command cables.
All the command and digital inputs / outputs can be in the same cable path.
If you have to cross the command/DC cables with the 400V/5A cables, it is recommended to cross with a right
angle.
Chapter : Commissioning
The grounding must be done in a proper way to avoid personal injuries and for a reduction of EMC.
8.1.3 Vibrations:
Caution: before starting the generating sets, please read the following part.
This is a standard commissioning for a simple power plant. If you use only this procedure, it can't
engage our responsibility.
During commissioning
Chapter : Commissioning
Start in safe condition
How?
Generator breaker output locked in open position.
Disconnect the wires between UNIGEN (terminals 17/18) and the speed governor.
Disconnect the wires between UNIGEN (terminals 20/21) and the AVR.
Ask the technician who had wired the power plant to lock the generator breaker open.
Battery negative of each UNIGEN power supply (terminal 2) must be connected to each other
UNIGEN and to the 0V of the speed governor.
Disconnect the wires of the relay ‘SYNC OK’ (terminals 34/35) of the UNIGEN.
Why?
To be sure not to drive a false paralleling during the beginning of commissioning.
Switches configuration
How?
Put switches in OFF/ON position before start the engine, see dedicated chapter “Settings” for
more details.
How?
Start the engine.
Adjust the nominal speed and voltage, for example 50.00Hz & 400VAC, on the speed/voltage
regulator. If a trim pot is present on the AVR, adjust it to get ±8% (see AVR manufacturer doc).
Stop the engine.
Remove the cover of the UNIGEN if necessary.
Connect only the REF input (terminal 18) to the speed governor “speed ref output”.
Speed setting :
Start the engine.
Adjust Speed gain RV10 full CCW on the UNIGEN.
Measure the voltage between Ref and remote voltage input on speed regulator side.
Adjust UNIGEN output voltage (terminals 17/18) adjusting the offset RV9 to have the same
voltage than measurement of previous point.
Connect the control wire (terminal 17).
Shunt terminals 15 and 16 together to get the maximal negative speed correction on
SPEED_SET input.
Adjust the speed gain RV10 to have 48.00Hz.
Remove the shunt between terminals 15 and 16.
Stop the generator.
Chapter : Commissioning
Voltage setting :
Adjust AVR Offset RV11 & Gain RV12 full CCW on the UNIGEN.
Connect AVR outputs (terminals 20/21) to AVR.
Adjust voltage offset RV11 to have 400VAC.
Close SYNC_IN input (Terminal 3 to 0 volts).
Adjust AVR Gain RV12 to reach 370VAC
Check the control of the breaker on dead bus (depending on SW6 position)
Be sure there is no critical load connected on bus bar.
Close the breaker and verify that the breaker feedback input (terminal 5) is closed
(BREAKER_IN LED should light on).
Open the breaker and verify that the breaker feedback input is opened (LED not lit).
Enter the number of the variable to modify (at first “11002”) and validate.
Chapter : Commissioning
Enter the new desired value and press SAVE button.
Repeat these steps for variables E11003 and E11004.
Go to page System/save all variables.
Click on "Flash it!”.
Disconnect UNIGEN, switch power off and then switch it on again for new settings to take
effect.
Finally, adjust the nominal power potentiometer as described below for engines above
200kW.
UNIGEN PLUS (Generating set with nominal power between 200kW and 4000kW):
Switch SW3 to OFF position.
Paralleling lines are not connected on terminals 44 and 45.
Close the circuit breaker of the generator. BREAKER_IN LED must light on.
Apply 100% of load on the generating set (with bench load for example).
Adjust NOMINAL_kW potentiometer RV13 to obtain 3V on parallel lines (terminal 44 & 45).
Open the circuit breaker of the generator.
Check synchronization
Close the breaker to have voltage on the bus bar (mains or other generator).
Lock the engine breaker in open position.
Start the engine to check the synchronization.
Close SYNC_IN input (terminal 3 connected to 0VDC).
Adjust P (RV15) & I (RV1) potentiometers of synchronization to reach a response time of 4 or 5
seconds to get the SYNC_OK signal (terminals 34/35) the relay closes.
With a voltmeter check on both sides of the breaker if the voltage is <20VAC on each phases.
With the voltmeter check also that there is 400VAC between phase 1 of the engine and phase
2 of the bus bar (crossed monitoring).
In this test we don’t close the breaker.
If the test is OK, connect the wires of the relay SYNC_OK (terminals 34/35) of the UNIGEN.
Chapter : Commissioning
9.1 CE directives
EMC Directive 89/336/EEC deals with electromagnetic emissions and immunity. This product is tested by
applying the standards, in whole or in part, which are documented in technical construction file CEM
2004/108/EC, which replaces directive CEM (89/336/EEC) relative to electromagnetic emissions as from July
20th 2009. This product is developed to respect harmonized norms:
EN 55099:2009
EN 55099:2010
EN 55088:2008
2006/95/EC (replaced directive 73/23/EEC since January 16th 2007).
Other standards:
EN 61326-1: 2006 (Industrial location)
EN 55011
Chapter : Environment
EN 61000-3-2
EN 61000-3-3
165mm
25mm
115mm
275mm 255mm
Chapter : Dimensions
25mm
200mm
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