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Operating Instructions
Control Unit for Gen. Power Sets
AUTOMATIC STAND-BY AND PEAK-LOAD CONTROL
Type: KEA 071-SPL
TA71SXXE.01
July 1996
(REPLACES 1994 EDITION)
TA71SXXE.01
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CAUTION !
This KEA unit shall be used only for purposes as announced in the written description
Installation and commissioning of equipment shall be executed by qualified persons only
Applicable rules, especially technical standards, as IEC or DIN VDE, have to be met strictly
On setting the parameters, it has to be watched, that hazards to persons or equipment are absolutely excluded
CONTENTS
Design
Page 3
Interconnections
Page 4
Page
Page
Page
Page 6
Page
Page
Page
Page
5
5
5
Page
Page
Page
Page
Page
7
7
7
7
8
Page 8
6
7
7
7
Fault signals
Page 9
Overspeed
Page 10
Battery undervoltage
Page 10
Fault signals No. 13 & 14
Page 10
Mains breaker failure / tripped
Page 10
Generator overcurrent /
Gen. CB tripped
Page 11
No engine set shut-down
Page 11
Synchronization failure
Page 11
Reverse power
Internal signals of volt. sensing
Page 11
Page
11
Standard connections & programs
Start sequence
Operate or shut-down solenoid
Run-up detection
Gensets frequency control
Peak-load supply
Additional signal contacts
Emergency stop / emergency off
Page 12
Page 12
Page 12
Page 12
Page 13
Page 13
Page 13
Page 13
Page 14
Page
Trouble shooting
Page 18
Parametering
Page 19
Technical data
Page 23
Page 23
TA71SXXE.01
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DESIGN
The components:
Automatic Generator set
KEA 071-SPL
Relay Unit RZ 071-D,
Relay Unit RZ 071-E,
Plug-in Cable Connection Set,
Unit
Flush-mounting unit
Protection degree (when installed): IP 44
Very compact design
Circuitry in SMD mode
Removable label strips for fault indicating and
operating push-button elements
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INTERCONNECTION
IMPORTANT NOTE:
The electrical connecting of control units
KEA 071 and RZ 071 are to be made by experienced experts only!
The Automatic Generator set Control Unit
KEA 071-SPL has to be connected with Relay Unit
RZ 071-D via plug-in connectors by means of the
attached multi-core cables.
The following signal wires have to be connected to
the Automatic Unit KEA 071-SPL directly:
Mains and generator voltage
Battery voltage (in case the internal battery
voltage sensor shall be used)
Measuring output of actual generator power
Measuring output of speed sensor (in case of
using a tacho voltage generator or a pick-up)
The supply voltage from battery, and all further
signal wires have to be connected to the Relay
Units RZ 071-D and RZ 071-E.
The battery voltage input is fitted with a false connection barrier, however, the correct polarity has
Indication
lights for
fault signals
(according
to order)
Push-button ON (I)
for mains / generator
Push-button OFF (0)
for mains / generator
Indication lights for
signal circuit closed
Push-button selector
Push-buttons
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OFF
On connecting the automatic unit to battery voltage, this operational mode position will be preselected automatically (Reset function), to prevent
the generator set from starting unintentionally.
On switching over from any other operational
mode, the following will be initiated:
Shut-down of generator set (if running);
OPERATIONAL MODE:
Switching-off of all indicated fault signals (except fault signals No. 13 and 14, if external
contacts should be still closed);
Reset of automatic unit, if locked out (provided,
the external EMERGENCY OFF contact is not
closed).
In case, mains voltage should be available, the
mains supply (i.e. mains circuit-breaker or contactor) will be switched on in this selector position.
HAND
TA71SXXE.01
OPERATIONAL MODE:
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AUTOMATIC
OPERATIONAL MODE:
07 / 96
TRIAL
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Change-over takes place with an overlap synchronizing or with an interruption, depending on signal
to terminal # 20 of relay unit RZ 071-D.
PUSH-BUTTON: START
Only when operational mode HAND is selected,
the starter motor can be energized and the engine
can be cranked by pressing the push-button
START. If the automatic units program is configured for a gas engine, this program sequence will
run. Should a diesel engine need a pre-glowing
To include in this test further signal lights, assembled in switchboard cubicle, a relay of relay unit
RZ 071-D has to be parametered and connected.
CONTROLS ON
After starting the generator set, this signal indicates the activating of monitoring circuits, which
are depending on generator sets run.
START INDICATION
This signal is lighting, if there is a starting demand,
processed by the control unit, or if the operational
mode HAND or TRIAL is selected.
TA71SXXE.01
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tion speed. Now, it is not possible, to actuate the
starter motor, not even manually.
any shut-down command emitted by the automatic control unit (with signal AUTOMATIC
UNIT LOCKED),
the generator set is still running even after
complete stop time has elapsed (without signal
AUTOMATIC UNIT LOCKED).
The CLOSED position of circuit breakers is indicated by green LEDs, arranged below the corresponding push-buttons. The LEDs are flashing, as
long as the synchronizing is active.
There are four red and two green LEDs each for
mains and generator voltage monitoring. They indicate normal conditions of each voltage system or
the character of deviation from normal.
The LEDs of first line, from left to right, are indicating:
Underfrequency (f<)
Voltage / frequency within normal range
Overfrequency (f>)
The second line of LEDs indicates:
Undervoltage / incorrect phase sequence (U<)
Voltage / frequency within normal range
Overvoltage (U>)
The signal UNDERVOLTAGE also will occur in
case of wrong phase sequence or in case of a
voltage vector asymmetry.
For voltage monitoring, the following parameters
may be entered:
Undervoltage: Response and disengage value
Overvoltage: Response and disengage value
Underfrequency: Response and disengage
value
Undervoltage,
Overvoltage,
Underfrequency, and
Overfrequency,
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LED indication along with fault signal
When parametered for fault alarm signals in case
of deviations from normal voltage or frequency
values, the alarm will be given only after response
delay time has elapsed. The green LEDs go out
and the red LEDs operate as normal fault signal
indicators, that means, they are flashing in case of
a faulty condition, and the audible alarm will sound.
As usual for all other fault signals, this signal triggers the general collective alarm output also.
FAULT SIGNALS
As a basic arrangement, the automatic control unit
KEA 071-SPL is fitted with facilities to process 22
single fault indicating circuits, 4 of which are provided for monitoring of mains and generator voltages, 14 are freely determinable by the user. Basically, there are three groups of fault signal processing:
1. Operation dependent fault signals (for example LOW OIL PRESSURE) will be active only,
when the generator set was started and an additional time lag has elapsed. Activation of
these monitoring circuits is indicated by LED
signal CONTROLS ON.
2. Operation independent fault signals (for example BATTERY UNDERVOLTAGE) are permanently active, except in case the push-button
selector is set to position OFF.
3. The fault signals No. 13 and 14 are active, independent of generator sets operation and of
selected operational mode. These monitoring
circuits are used for permanently needed alarm
information, even if the push-button selector
should be set to position OFF (for example
LEAKAGE). In position OFF, the audible signal
will not be energized, but this signal triggers the
general collective alarm output also. Any other
operational mode (except OFF) causes usual
processing of these fault signals.
The fault signal processing may be configured, depending on the actual execution of circuitry, as follows:
For signal contacts in NO (normally open) or in
NC (normally closed) circuits;
Delayed or undelayed operation dependent
alarm;
Signals effecting a warning only or an additional
generator set shut-down;
Additionally, for warning signals:
- without generator breaker tripping;
- with immediate generator breaker tripping;
Mains undervoltage
Mains overvoltage
Mains underfrequency
Mains overfrequency
Generator undervoltage
Generator overvoltage
Generator underfrequency
Generator overfrequency
When using control contacts, the alarm will be released on contact closing (NO circuits) or on contact opening (NC circuits). With analog value inputs, the alarm condition is released, when the
pre-set limit values will be passed. Each alarm will
be indicated by the corresponding LED with flashing light and by audible alarm (for the configured
duration).
To silence the audible alarm, a pulse has to be
given by push-button ALARM OFF; otherwise, the
alarm will be switched off automatically (when parametered time has elapsed). On silencing the audible alarm, the LED signal changes to steady
light. Several alarms, which could occur in sequence, would repeatedly release the audible
alarm; each alarm is indicated by a separate LED.
In case of warning alarms, another pulse by pushbutton ALARM OFF will cancel the visible signal,
provided, the matter of alarm has been eliminated.
In case of signals, which lead to a shut-down of
generator set, any subsequent operation is locked
out by the automatic control unit. This condition is
shown by the LED signal AUTOMATIC DEVICE
LOCKED. To reset the automatic control unit, after
having eliminated the faulty condition (unlocking of
an external EMERGENCY STOP push-button included), the push-button selector has to be set to
TA71SXXE.01
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OVERSPEED
To watch the overspeed condition, the generator
frequency, or the frequency of a separate speed
sensor (pick-up or tacho generator) has to be detected.
When using the generator frequency, it is necessary to configure the fault signal GENERATOR
UNDERVOLTAGE as a shut-down signal. This
procedure makes sure, that in case of loss of
generator voltage the engine set will be shutdown.
For these signal circuits, the following parameters
may be set:
Limit speed for response;
Disengaging value;
No. of fault signal indication, which shall be
coupled.
BATTERY UNDERVOLTAGE
This warning signal has to be parametered as being active, independent of engine run.
To monitor this signal properly, the voltage supply
for automatic control unit KEA 071-SPL has to be
connected to another source than the monitored
battery
(see
National
Standard
DIN VDE 0108/10.89, Part 1, Section 6.4.4.5, or
comparable International Rules).
This may be (as for example in large installations)
a common control potential, supplied by several
existing batteries, which are uncoupled by diodes.
For monitoring the battery voltage, additionally an
integrated battery voltage sensor may be config-
Response value,
Disengage value,
Delay time,
No. of fault signal indication, which shall be
coupled.
TA71SXXE.01
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ple, when a burned shut-down solenoid or a defective gas valve would prevent the engine from stopping.
TA71SXXE.01
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07 / 96
all other fault signals, this signal triggers the general collective alarm output also.
When voltage or frequency deviations are configured as fault signal indications, the following parameters (as usual for other signals) have to be
entered:
A fault signal indication is not influencing the voltage monitoring; that means for instance, the warning
indication
GENERATOR UNDERFREQUENCY, once initiated, will not be cancelled,
when frequency has returned to normal. However,
the correct frequency will be known by the automatic units program.
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TA71SXXE.01
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nected to control outputs, shall have antiinterference protection!
TA71SXXE.01
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On the event of activating the generators unloading, a timer will be started. When the configured
time has elapsed, without any unloading, probably
the speed control circuit may be faulty, and the
generator breaker also will be tripped, independent
of actual load.
In case of performing an external power controller,
the signal UNLOADED has to be led to relay unit
input.
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EMERGENCY SHUT-DOWN
GENERATOR OFF
MAINS OFF
supply (in operational mode TRIAL) and the reconnection to mains supply (in operational mode
TA71SXXE.01
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TERMINAL 21:
Any start attempt, emitted manually or automatically, will be interlocked as long as there is no L[-]
potential connected to terminal No. 24. So, it is
possible to incorporate relevant pre-start conditions, before a signal to starter motor for cranking
will be given. In case this function is not
needed, a wire jumper from L[-] to terminal
TERMINAL 25:
On connecting this input terminal 23 to L[-] potential, all the fault sensing circuits are leading to
warning alarms only. But, using the parametering
program, on pressing key F5 and entering a valid
key number, the signal circuit for sensing OVERTERMINAL 24:
PEAK-LOAD DEMAND
07 / 96
TA71SXXE.01
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Junction
Junction
Junction
Junction
Junction
Junction
5:
6:
7:
8:
9:
10:
When measuring input 7 is used for battery voltage monitoring, the terminal points 3 and 5 of terminal
strip -X 401 shall not be bridged, because the burden would amount to 240 !
In this case, a jumper between the two terminals would destroy the measuring input!
TUMBLER SWITCH
The tumbler switch, arranged at the rear side of
automatic unit KEA 071-SPL, under the protection
hood covering the analog equipment, has to be set
in accordance with connected unit:
): Pick-up
): Tacho generator
TROUBLE SHOOTING
In case of malfunctions occurring during commissioning or operation, origin of which are not
straight-away clear, at first all peripheral conditions of the complete control system should be
checked carefully. Considering the elevated grade
of integration of KUHSE automatic control units
circuitry, a failure or defect in the internal system
TA71SXXE.01
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When measuring the tacho generator voltage,
use oscilloscope or high-ohmic instrument
only!
Verify, that switchboard equipment (for example, contactor coils) is sufficiently protected
against emitting high-voltage peaks, for instance by RC suppresser elements.
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PARAMETERING
On request, the parameters will be shop-adjusted. For
this purpose, please send a copy of the list below, with
filled-in required values.
The following table shows the standard shop-configuration, which is executed in case of no special customers
requirements. However, all values may be entered or
varied later, using a PC or a laptop. The label stripes of
fault signal indications may be printed with a PC write
program; the labels are easy to exchange. Values that
are configurable are identified by squared brackets [ ].
OPERATE SOLENOID
[2 sec]
[7 sec]
sec
CRANKING INTERVAL
[7 sec]
sec
CONTROLS ON DELAY
[7 sec]
sec
RE-CONNECTION DELAY
[60 sec]
sec
[180 sec]
sec
SHUT-DOWN TIME
[30 sec]
sec
[2 sec]
sec
[2 sec]
sec
YES
UNDERVOLTAGE
[ ]
NO
YES
NO
CODING
[185 / 205 V]
[ ]
[ ]
[264 / 250 V]
UNDERFREQUENCY
[ ]
[48 / 49 Hz]
H
z
AS FAULT SIGNAL?
[ ]
OVERFREQUENCY
[ ]
[52.1 / 51 Hz]
H
z
AS FAULT SIGNAL?
[ ]
AS FAULT SIGNAL?
[ ]
OVERVOLTAGE
AS FAULT SIGNAL?
DELAY ON EXCEEDING:
[4 sec]
sec
DISENGAGE DELAY:
[4 sec]
sec
DELAY ON UNDERPASSING:
[1 sec]
sec
YES
UNDERVOLTAGE
[ ]
NO
YES
NO
CODING
[185 / 205 V]
AS FAULT SIGNAL?
[ ]
OVERVOLTAGE
[ ]
[ ]
[264 / 250 V]
AS FAULT SIGNAL?
UNDERFREQUENCY
[ ]
[48 / 49 Hz]
H
z
AS FAULT SIGNAL?
[ ]
OVERFREQUENCY
[ ]
[52.1 / 51 Hz]
H
z
AS FAULT SIGNAL?
[ ]
DELAY ON EXCEEDING:
[4 sec]
sec
RESET DELAY:
[4 sec]
sec
DELAY ON UNDERPASSING:
[1 sec]
sec
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CODING
FAULT SIGNAL
[GENERATOR OVERCURRENT]
[RUG0]
FAULT SIGNAL
[SHORT CIRCUIT]
[RUS0]
FAULT SIGNAL
[AVS0]
FAULT SIGNAL
[ENGINE OVERTEMPERATURE]
[AVS0]
FAULT SIGNAL
[LACK OF FUEL]
[AUG1]
FAULT SIGNAL
[OVERSPEED]
[AUS0]
FAULT SIGNAL
[BATTERY UNDERVOLTAGE]
[AUG1]
FAULT SIGNAL
[AUG1]
FAULT SIGNAL
[AUG1]
FAULT SIGNAL 10
[AUG1]
FAULT SIGNAL 11
[AUG1]
FAULT SIGNAL 12
[AUG1]
FAULT SIGNAL 13
[AUG1]
[0 sec]
sec
FAULT SIGNAL 14
[AUG1]
[15 sec]
sec
R=
NORMALLY CLOSED
U=
UNDELAYED
G=
ALARM CONDITION
1=
A=
NORMALLY OPEN
V=
DELAYED
S=
SHUT-DOWN CONDITION
0=
GENERATOR CB TRIPPING
[7]
OVERSPEED
[6]
[1]
[0]
[0]
SYNCHRONIZATION FAILURE
[0]
SPEED DETECTING
SPEED DETECTING BY:
[CHARGING DYNAMO]
[1500 min-1]
TACHO GENERATOR
min-1
[50 Hz]
Hz
PICK-UP
GENERATOR FREQUENCY
Hz
FIRING SPEED;
RATED SPEED;
OVERSPEED );
1
[80 / 70 min-1]
min-1
min-1
min-1
min-1
-1
-1
) Required only , when start sequence program is configured to control gas engines (Tacho generator or pick-up required!).
) If no tacho generator or pick-up is available, the speed will be detected out of generator frequency. In this case, GENERATOR UNDERVOLTAGE has
to
be configured as shut-down signal.
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INTERNAL BATTERY MONITORING PROVIDES, THAT PROGRAM FOR SLIDING POWER VALUE CONTROL (UNDER
PEAK-LOAD CONDITION) IS NOT CONFIGURED!
RESPONSE VALUE 1)
[12.6 V]
RESET DELAY:
1
[25.2 V]
[60 sec]
RESET VALUE
[12.9 V]
sec
Voltages less than 2.1 V/Cell (Lead-acid batteries) or less than 1.3 V/Cell (Cd-Ni batteries) shall release an alarm!
NO []
[49.8 Hz]
Hz
[49.8 Hz]
Hz
[1.0 sec]
sec
[3.0 sec]
sec
YES
YES []
[0.3 Hz]
NO
Hz
[8 %]
[100 ms]
ms
[1.0 sec]
sec
[3.0 sec]
sec
[180 sec]
sec
YES []
NO
YES []
NO
[]
NO
YES
kW
kW
kW
kW
[1.0 sec]
sec
[20 sec]
sec
[3 sec]
sec
[180 sec]
sec
[10 sec]
sec
[25.7 V]
kW
) When sliding power value control is not enabled, the constant power control is selected automatically.
TA71SXXE.01
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-K 4
-K 5
-K 8
-K 9
-K 10
-K 11
-K 12
-K 13
-K 14
-K 15
-K 16
-K 17
-K 18
-K 19
-K 20
-K 21
-K 22
-K 23
-K 24
-K 25
-K 26
Starter relay
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TECHNICAL DATA
15 %
POWER SUPPLY
2A71S
3 x 100 V
3 x 230/100 V
3 x 400 V
Example:
Extension:
0
3 x 100 V
3 x 230/400 V
3 x 400 V
without extensions
3 x 100 V
3 x 230/400 V
RZ 071-D:
2R71D00
3 x 400 V
RZ 071-E
2R71E00
3 x 100 V
1K71100
3 x 230/400 V
1K71150
3 x 400 V
1K71250
Automatic unit KEA for mains stand-by and peak-load operation, suitable for mains and
generator voltage 3 x 230/400 V, fitted with integrated automatic synchronizer and active
power control:
Order Number:
2A71S50
TA71SXXE.01
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OUTLINE DRAWINGS
RZ 071-D
CONNECTION DIAGRAM
RZ 071-E