Está en la página 1de 94

Update List

No. Date Changes, additions Name Release


Replace previous documents, documents not
mentioned remain valid
1 07.09.2006 Basisversion Mörderisch
Robert
2 10.01.2007 Basisversion in Sprache Englisch überarbeitet Mörderisch
Robert

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 2 von 94 24.01.2007


Inhaltsverzeichnis
1. General 5
1.1. MMC System Description....................................................................................................5
1.2. "MTU motor management" system description...................................................................5
1.3. Safety instructions ................................................................................................................5
1.4. Safety chain ..........................................................................................................................5
1.5. CPU ......................................................................................................................................5
1.6. Selectivity of the Protective Equipment...............................................................................5
1.7. Shielded Cables ....................................................................................................................7
1.8. Circuit Diagram Documentation ..........................................................................................7
1.9. Maintenance .........................................................................................................................7
2. Start/Stop Procedure 8
3. Operating Conditions 12
3.1. “Manual” Operating Mode.................................................................................................12
3.2. “Automatic” Operating Mode ............................................................................................12
3.3. Grid Standby Operation .....................................................................................................12
3.3.1. Grid standby operation via external control instrumentation (not MCS)...................12
3.4. System (grid) connection: ..................................................................................................13
4. Floating Contacts 14
5. Operation & Display 15
5.1. Selector Switch / Button / Emergency stop (switching system) ........................................15
5.2. Display ...............................................................................................................................17
5.3. Parameter Entry..................................................................................................................17
5.4. Description of the Menu Bar ..............................................................................................18
5.5. Login ..................................................................................................................................21
5.5.1. Login with user and password....................................................................................21
5.5.2. Login via hardware USB dongle (optional) ...............................................................21
5.6. Main Menu .........................................................................................................................22
5.7. Plant Overview...................................................................................................................22
5.8. Engine Overview................................................................................................................23
5.9. Electrical Data ....................................................................................................................24
5.10. Water System .................................................................................................................29
5.11. Gas System .....................................................................................................................30
5.11.1. Alternative gas operation with two gas routes (optional) ..........................................30
5.11.2. Alternative gas operation with just one gas route (optional) .....................................30
5.12. Additional Function: Gas Compressor (optional) ..........................................................31
5.13. Gas Leak Test.................................................................................................................32
5.14. Oil System ......................................................................................................................33
5.15. Fault Alarm ....................................................................................................................35
5.16. System Status Indications...............................................................................................35
5.17. Alarm log........................................................................................................................36
5.18. Power Controller ............................................................................................................38
5.19. Start / Stop Procedure.....................................................................................................42
5.20. Counter reading ..............................................................................................................43
5.21. Overview of Auxiliary Features .....................................................................................44
5.22. Cleaning Window...........................................................................................................44
5.23. Additional Function: Water Temperature Controller (optional) ....................................45
5.24. Additional Function: Mixture Water Controller (optional)............................................47
5.25. Additional Function: Mixture fan and pump (optional).................................................47
MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 3 von 94 24.01.2007
5.26. Additional Function: Emergency Cooling Water Controller (optional) ........................49
5.27. Additional Function: Emergency cooler fan and pump (optional) ................................49
5.28. Additional Function: Room Temperature Controller (optional) ....................................51
5.29. Additional Function: Room Air Fan Control (optional) ................................................51
5.30. Additional Function: CH4 Regulation (optional)...........................................................54
5.31. Gas Tank (optional)........................................................................................................56
5.32. Grid feed control (optional)............................................................................................58
5.33. Exhaust / Bypass Butterfly Valve Control (optional) ....................................................61
5.34. Heat operation motor (optional).....................................................................................62
5.35. Heat operation boiler (optional) .....................................................................................66
5.36. External temperature shift (optional) .............................................................................67
5.37. Heating Water Reservoir (optional) ...............................................................................68
5.38. Additional Function: Timer (optional)...........................................................................69
5.39. Additional Functions: SMS/e-mail (optional)................................................................71
5.40. Service menu ..................................................................................................................72
5.41. External Communication (optional)...............................................................................73
5.41.1. Interface protocol: general notes ................................................................................75
5.42. M-Graph: Single channel intraday .................................................................................76
5.43. M-Graph: Single channel ...............................................................................................77
5.44. M-Graph: System ...........................................................................................................78
6. Operation & display: Service menu 79
6.1. System overview ................................................................................................................80
6.2. Fault alarm parameters .......................................................................................................81
6.3. Parameters ..........................................................................................................................82
6.4. Analog parameters..............................................................................................................83
6.5. Options parameters.............................................................................................................84
6.6. Emergency cooler parameters ............................................................................................85
6.7. Room fan parameter ...........................................................................................................86
6.8. Heat operation parameter ...................................................................................................87
6.9. Test Facility........................................................................................................................88
6.10. M-Graph: Single channel ...............................................................................................89
6.11. M-Graph: Single channel intraday .................................................................................89
6.12. M-Graph: System ...........................................................................................................89
6.13. M-Graph: System intrady...............................................................................................89
6.14. M-Graph: Heating Water ...............................................................................................90
7. Hardware descriptions 91
7.1. IPC......................................................................................................................................91
7.1.1. Possible fault causes...................................................................................................91
7.1.2. Establish remote access (e.g. customer).....................................................................91
7.2. Interface modules for control .............................................................................................91
7.3. CP3485 ...............................................................................................................................92
7.4. MSP....................................................................................................................................93
7.5. LAP 2440-3 Battery charging device.................................................................................94

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 4 von 94 24.01.2007


1. General

1.1. MMC System Description


Industrial PC with touchscreen and various interfaces, „Windows XP Embedded“operating
system

Programmable Logic Control, programming to IEC 1131-3

Various interfaces (e.g. Ethernet, Profibus, RS232, Modbus RTU, … )

MDE Synchronization & Protection

The module control box contains functions for system components related to the motor. Various
controls (heating water, grid feed, gas tank…) and auxiliary drive actuators are integrated into
the system.

1.2. "MTU motor management" system description


MTU motor management contains all monitors and controls required for running the gas motor.
Communication with the MMC is per CAN bus. The current motor data (analog values, status
messages) and fault messages are transferred here.

1.3. Safety instructions


The system may only be operated by authorized employees of the operating company.
Maintenance and switching work may only be by external staff if authorized employees of the
operating company are present.

The regulations of the accident prevention and insurance association must be observed when
working on the switching system.

Safety devices may only be replaced by authorized employees using the appropriate tools.

The manufacturer’s maintenance regulations must be observed.

1.4. Safety chain


The safety chain is equipped with two safety combinations tested according to category 2:

Machine safety chain (e.g. STB, combined emergency stop from PLC, ...)
Manual emergency stop safety chain (e.g. emergency stop at module cabinet, building
emergency stop, …)

If one of the safety chains is actuated, the corresponding drives are deactivated (e.g. gas valves, ...).
All drives are deactivated if the emergency stop is actuated manually.

1.5. CPU
The CPU of the PLC is monitored by a watchdog. If it is actuated, all PLC outputs are shut down safely
and the safety chain is actuated. The CPU can only be reset by restarting (switching the safety cut-out
off and on). If the fault occurs again, contact the service department.

1.6. Selectivity of the Protective Equipment


The selectivity of the protective equipment (fuses, power switches, …) in the switching system is
designed is designed for short-circuit current in grid standby or parallel operation. In grid standby
operation, only the lower short-circuit currents of the connected generators are available. The selectivity
MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 5 von 94 24.01.2007
of the protective equipment is restricted in grid standby operation. The operator must ensure that the
selectivity of the protective equipment is guaranteed in the consumer switching system in this operating
condition.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 6 von 94 24.01.2007


1.7. Shielded Cables
The shield must be attached very close to the contact point.
The shield must be attached on one side (module cabinet).
The unattached side of the shield must be insulated.

1.8. Circuit Diagram Documentation


The circuit diagrams are adapted specifically for each system. The diagrams are drawn up using the
“WSCAD” drawing system. The following documentation is available after the circuit diagrams have been
created:

1. Circuit diagrams (wiring diagram)


2. Cable lists
3. Parts lists
4. Terminal diagrams

1.9. Maintenance

The CP3485 (PLC) control unit is fitted with a battery. This battery must be replaced at regular intervals
in accordance with maintenance regulations. When necessary, the filter mat of the filter fan must be
cleaned.

Maintenance intervals:
• Replace the battery in the CP3485 (PLC) central unit every 4 years or as necessary.
• Clean/replace the filter mat when necessary

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 7 von 94 24.01.2007


2. Start/Stop Procedure

Start procedure – Part 1


Start command (local / remote) & manual/ or automatic mode
Start requirements 1
key switch enable, assembly is ready for operation,
no grid fault pending (for plant without grid standby, NLS is on
or "No NLS" option)
Automatic: All start conditions ok for automatic mode!

No No start command to MTU motor management


Yes

Start command to MTU motor management, Activate


Phase 1 auxiliary drives, activate cooling water pump, open exhaust flaps.
Start leak test (Request from MTU motor management)

Auxiliary drives on, cooling water pump on, exhaust flaps open,
Start requirements 2 leak test ok.
(Auxiliary drives on + leak test ok message to MTU
motor management)

No Cancel start – Phase 1 by MTU motor management

ja

Phase 2 Open gas valves (Request from MTU motor management)

Gas valves are opened. (Gas valves open message to MTU


Start requirements 3
motor management)

No Start cancel – Phase 2 via the MTU motor management


Yes

To phase 3

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 8 von 94 24.01.2007


Start procedure – Part 2

Wait
Wait until
until rated
rated speed
speed reached.
reached.
Phase 3 Generator
Generator voltage monitoring
Activate
voltage monitoring ++ generator
generator frequency.
frequency.
Activate overtravel
overtravel time
time for
for auxiliary
auxiliary drives.
drives.

Start
Rated
Rated speed
speed reached
reached (message
(message from
from MTU
MTU motor
motor management).
management).
Startrequirements
requirements 44
(Generator
(Generator voltage
voltage >> limit
limit value)
value) &
& (generator
(generator frequency
frequency >> limit
limit value).
value).

No
No Start
Start cancel
cancel –– Phase
Phase 33
Yes
Yes

Enable
Enable synchronisation
synchronisation (automatic
(automatic or
or manual).
manual).
Enable
Enable speed
speed adjustment.
adjustment. Automatic:
Automatic: Enable
Enable synchronisation
synchronisation ++
Phase 4 Start
Start time
Manual:
time monitoring.
monitoring.
Manual: NoNo synchronisation
synchronisation release
release

Start
Startrequirements
requirements 55 Generator
Generator switch
switch isis on
on ++ time
time monitoring
monitoring not
not complete
complete

No
No
Start
Start cancel
cancel –– Phase
Phase 44
Yes
Yes

Parallel
Parallel grid:
grid: Monitoring
Monitoring the
the power
power control,
control, gradient
gradient
Grid
Grid standby:
standby: Activate
Activate grid
grid standby
standby mode
mode (frequency
(frequency controller)
controller)

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 9 von 94 24.01.2007


Stop procedure – Part 1

Phase 0 Genset
Genset in
in operation
operation and
and stop
stop pending.
pending.

Slow
Slow stop
stop (gradient
(gradient function)
function)
Stop
Stopcondition
condition00 or
or
Fast
Fast stop
stop (open
(open switch)
switch)

Fast
Fast Jump
Jump to
to phase
phase 22 immediately!
immediately!
Slow
Slow

Phase 1 The
The genset
genset isis unloaded
unloaded (gradient
(gradient function).
function).

Stop
Stopcondition
condition11 Power
Power dropped
dropped below
below minimum.
minimum.

No
No Stays
Stays in
in phase
phase 11 !!

Yes
Yes

Open
Open generator
generator switch,
switch, activate
activate speed
speed control,
control,
Phase 2 Start
Start overtravel
Stop
overtravel time
time for
for auxiliary
auxiliarydrives.
drives.
Stop command
command to to MTU
MTU motor
motor management.
management.

Module ready to start!

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 10 von 94 24.01.2007


Emergency stop procedure

Phase 1 Genset in operation and emergency stop pending

Machine emergency stop


Manual emergency stop
(no manual emergency stop)

Phase 2 Phase 3

Stop command to MTU motor management

The following functions are always


performed:
-Close gas valves
-Open generator switch
-Switch to speed control
Stop command to MTU motor management
Various auxiliary drives may overtravel:
Cooling water pump
-Exhaust flaps
-Heating water pump
All functions are -Bypass flaps
deactivated without -Lubricating oil supply
-Ventilation
delay !
Exception:
One of these functions triggered an
emergency stop, then it is also
deactivated.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 11 von 94 24.01.2007


3. Operating Conditions

3.1. “Manual” Operating Mode


In this mode, the genset is started when the start command is sent (all start requirements must be
fulfilled) and run until in the idle state. The genset remains in the idle state (max. 2 h) until the
synchronization process is started or the stop button is pressed. After synchronization has been started
and performed successfully, a setpoint of approx. 10% is set for the power controller. The power can
now be controlled manually.

3.2. “Automatic” Operating Mode


In this mode, the genset starts automatically and synchronizes itself with the network when the start
command is sent. The current setpoint is sent to MTU motor management and targeted, depending on
the operating characteristics selected (set-value control, flexible value control, heat-controlled operation.

In automatic mode, various additional functions are incorporated in the start sequence.
Depending on the active function (e.g. timer, power draw regulation, CH4 content etc.), the
start release of the respective function is incorporated when the start command is activated.
If this is not the case, a combined alarm is signaled.
If a drive or a controller (e.g. cooling water pump, heating water pump etc.) is set to manual
mode and an automatic start is initiated, manual mode is reset (e.g. would overheat the
genset if the cooling water pump was off).

3.3. Grid Standby Operation


In isolated mode, the power output is determined by the connected consumer loads. The speed
control system must simply adjust back to the setpoint value following a load change. A frequency
controller supplies this setpoint value. In the case of multi-engine plants, gensets operating in
parallel must not burdened with different percentages of the load. An active-power load sharing
system is provided to prevent this problem. It compares the generator active-power signals of the
participating gensets and continues to supply adjustment signals using the remote governors to the
speed control systems of the individual gensets until the loads are equalized (P range is 3 ... 5%).
A frequency controller simultaneously supplies equidirectional adjustment pulses to all speed
governors to eliminate any frequency deviations as quickly as possible. An internal logic prevents
contradictory signals from occurring as a result of power and frequency variations.

3.3.1. Grid standby operation via external control instrumentation (not MCS)
See separate document "Grid standby via external control instrumentation"

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 12 von 94 24.01.2007


3.4. System (grid) connection:
Synchronous generators may only be connected to an existing grid if voltage, frequency and phase
angle are identical. A synchroniser is necessary in order to ensure that these conditions can be met.
The synchroniser acts in conjunction with the speed controller to adjust the frequency and speed of
the generator to enable system connection. Following system connection, the synchroniser is
switched off.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 13 von 94 24.01.2007


4. Floating Contacts
By default, the controller outputs various floating contacts. These contacts can be used to activate various
drives or to query the system status. More of these kinds of signals can be sent for a specific project.

Ready:
This contact remains closed when the following criteria are fulfilled:
Key switch is set to module release
Key switch is set to remote
Key switch is set to automatic
No stop or emergency stop signal is pending

External auxiliary drive on:


The contact is activated during start-up. When the motor reaches the operating conditions, the overtravel
timer is activated. When the genset is stopped again, the overtravel timer for the auxiliary drives runs down.
This cools the motor. The contact is not deactivated until after the overtravel time.

The auxiliary drives are always switched off when an emergency stop is activated (safety chain
actuated).

The auxiliary drives are also activated once for an overtravel if a PT100 temperature (HZW
temperature inlet/outlet, MCW temperature inlet/outlet) is exceeded on the heat module. This is
intended to dissipate any built-up heat and to return the motor to the ready state.

GePS is on:
The contact is activated as soon as the generator switch is closed.

“Stop” combined signal:


The contact opens when a stop or emergency stop signal is pending. The machine shuts down and the
ready signal is switched off.

Motor is running:
The contact is closed as soon as the motor reaches a speed of over 1000 rpm.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 14 von 94 24.01.2007


5. Operation & Display

5.1. Selector Switch / Button / Emergency stop (switching system)


Name Type of switch Position
Module release Key switch 0/1
Description
This switch prevents the module being operated. If the machine is idle, the
module cannot be started. If the machine is running, a regulated stop is initiated.

0 = No release; 1 = Release

Name Type of switch Position


Local / remote control Key switch 0/1
Description
This switch sets the operation location. If the system is to be operated
directly from the module, the switch must be set to “Local”. This allows all
setpoints to be changed using the IPC. It also activates the “Start / Stop
switch” on the control cabinet. If the system is to be operated remotely
(remote start / stop, remote setpoints, control via interface), the switch must
be set to “Remote”.

0 = Local operation; 1 = Remote operation

Name Type of switch Position


Manual / automatic Key switch 0/1
Description
In automatic mode, the system is started when the start signal is received,
and the module is automatically synchronized with the grid and driven
(gradually) to the power setpoint entered. All control tasks are performed
automatically. The system is started after a start command in manual mode.
The module starts and remains in the synchronization-ready state after the
set speed is reached. In this phase, the speed can be adjusted manually
(higher / lower pulses). Synchronization can be initiated by pressing another
button (on the display). After successful synchronization to the grid, the
machine stays at the minimum setpoint (approx. 10% power). The setpoint
must be changed manually. All control tasks are performed automatically.
“Local control” must be set for manual operation.

0 = Manual mode; 1 = Automatic mode

Name Type of switch Position


Start/Stop Key switch 0/1
Description
This switch is used to start the module locally. The “Local / remote control”
key switch must be set to “Local”.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 15 von 94 24.01.2007


Name Type of switch Position
Grid standby operation release Key switch 0/1
Description
Automatic grid standby operation can be released using this switch. If this is
the case, grid standby operation is initiated if there is a grid fault or a grid
switch cabinet. In manual mode, the power switches (generator [GePS] and
grid [GrPS]) can be operated manually (open, close). If grid standby mode is
not released, the power switch (GePS) is opened immediately if there is a
power failure.

0 = No release; 1 = Release

Name Type of switch Position


Grid failure test Key switch 0/1
Description
This switch is used to test the effects of a grid failure. A phase to MSP
(MDE Synchronization & Protection) is interrupted when the button is
pressed. The reaction actuated depends on the position of the “Grid standby
operation” key switch. If it is released, the grid standby is initiated; if not the
GePS is opened.

0 = No test; 1 = Start test

Name Type of switch Position


Reset Button
Description
This button is used to acknowledge pending fault alarms. The safety relays
are opened when an emergency stop is pending. The safety relays and the
corresponding fault alarms can only be activated or acknowledged using this
button. Only fault alarms for which no relay must be activated can be
acknowledged via the display (R-button).

Name Type of switch Position


Emergency stop switch Emergency stop
Description
The manual emergency stop chain is actuated immediately when the emer-
gency stop switch is activated. All drives and the module are deactivated
immediately. The emergency stop chain cannot be activated again until the
switch has been unlocked (the switch can be unlocked using a key) and the
reset button has been pressed.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 16 von 94 24.01.2007


5.2. Display
All values imported from the module and the plant can be shown on the integrated touchscreen. The display
is made up of various menus. The display is designed for touch operation. All operations can be performed
without a keyboard or mouse. All entries can also be made using software keyboards. Various menus,
parameters and switches are only released for certain users (no release => greyed out).

You must press the button and log in to activate them. The menus or parameters are
released if the user is authorized.

If no user is logged in, all operations and parameters are blocked!

5.3. Parameter Entry


All plant parameters required can be changed using the display. Parameters can be identified by the red text
color. When these parameters are clicked, an entry window opens.
Enter the parameter (by pressing the number buttons) and press “Enter” to confirm.

All parameters are monitored for the entry ranged. If the entry is outside the entry range, the value is
changed automatically to the upper / lower threshold.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 17 von 94 24.01.2007


5.4. Description of the Menu Bar

Home Button
Press this button to return to the start screen. You can keep pressing this button until the “Main menu” is
opened.

Help Button
Press the Help Button to view the version number of the current display and the control program on the PLC.

Only available from the main menu!

Language Selection Button


This button is used to change the language. Two languages are always stored (German, English). The
national language can also be integrated as a third language.

Only available from the main menu!

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 18 von 94 24.01.2007


Fault Alarm Button
This button indicates when a fault alarm is pending. These buttons are each linked with a combined fault
alarm. Press one of the buttons to switch to the fault alarm window.

There are three types of fault alarms:

Emergency stop (E):


The system is switched off immediately, e.g. when the emergency stop button is pressed.

Stop (S): (Red alarm)


The system is stopped. This can be either a “controlled stop” or an “immediate stop”.

Controlled stop: The module is relieved of the power load gradually.


Immediate stop: The power switch is opened without delay.

Alarm (A): (Yellow alarm)


A fault has occurred which dies not cause the module to be deactivated.

The following states apply for all three buttons:

No fault:
The button is “blue”.

A new fault is pending and has not been acknowledged:


The button is “red” and flashing.

A fault is pending and has already been acknowledged:


When a combined fault is pending and the operator has already acknowledged it (by pressing the
“reset button”), the button turns “yellow” and no longer flashes.

Start Request
If this button is red => there is no start request at the moment.
If this button is green => there is a start request (e.g. remote control & remote start command
pending).

Press this button to list all start conditions for automatic mode. All functions activated in the system are
enabled and indicated. If the start condition is fulfilled (e.g. the gas tank enables the system), the gas tank
LED lights green (if not, then it is red). This makes it easy to see which start conditions are missing.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 19 von 94 24.01.2007


Date/Time Button
This button is used to set the time and date of the controller and the IPC. The project name is only displayed.

You can set the time and date of the controller and the IPC on this page. The time is important for marking
the time of fault alarms. The data is entered in the red fields and then transferred to the controller by
pressing the “Set time” button. If the transmission was successful, the current time (the values set) are
shown on the left side and the second counter runs. The “Acknowledge alarm” button flashes when a fault is
pending. This button must be pressed to acknowledge the fault and to allow you to repeat the procedure.

Attention: The year cannot be set earlier than 2000.

Nur vom Hauptmenü aus möglich!

Login-Button
This button is used to release various parameters and menu items for users.
Certain parameters are released for each user. This prevents unauthorized persons changing critical
parameters.

Only available from the main menu!

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 20 von 94 24.01.2007


5.5. Login
This button is used to log in as a defined user. Different parameters and menus are enabled according to
the user logged in. For example, it may be possible to change the parameters of the room fan. You can
only login in the main menu.
The following two types of login are available.

5.5.1. Login with user and password


For login this way you have to enter user and password in the Login form.

Standard user and password:


You will get this information separate from the operator manual.

Procedure:
Press the “Login” button
The login form opens.

Enter the “User” and the “Password” (touch the corresponding entry field).
Press “Login” in the login form.
The current User, Level and Logout time are shown in the Status bar.
The window closes automatically after a short time.

Users are logged off automatically after a certain time.

If the entry is incorrect, “Wrong User or Password” appears in the Status bar.

5.5.2. Login via hardware USB dongle (optional)


For this login type, no user or password must be entered. A USB dongle is inserted in the front USB port of
the IPC, and then only the login button in the login window needs to be clicked. The computer checks the
dongle and then enables the access level saved on the dongle. There is no automatic logout while the
dongle remains inserted. When the dongle is removed, the user level is reset to 0 within 10 minutes.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 21 von 94 24.01.2007


5.6. Main Menu

The main menu appears automatically when the PC starts. This screen is the highest display level. Use the
menu buttons to open the various sub-screens.

5.7. Plant Overview


The plant overview varies from project to project. Plant-specific data are displayed on this page.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 22 von 94 24.01.2007


5.8. Engine Overview
Auf dieser Seite wird je nach Motortyp eine Übersicht aller Aufnehmer und Messwerte dargestellt.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 23 von 94 24.01.2007


5.9. Electrical Data
This screen contains all important data on the generator and the grid. The overview and data depend on the
options selected (e.g. with grid standby).

The GePS can be operated manually from this screen (the GrPS can also be controlled as an option for grid
standby plants).

The following requirements must be fulfilled:

“Local/remote” key switch set to Local

“Manual/automatic” key switch set to Manual

Authorized user logged in

The GrPS can only be activated manually in a grid standby plant.

GePS:
The “Close” button does not cause asynchronous activation of the grid switch if the GrPS is closed.
In the idle state, the switch cannot be closed.

GrPS:
The “Close” button does not cause asynchronous activation of the grid switch if the GePS is closed.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 24 von 94 24.01.2007


Load Level Control (optional)

It is possible to activate load release control in grid standby operation. Control is possible up to eight levels.
When grid standby is initiated, control system issues the “Load release” command. Grid standby is then only
resumed after a message has been received to say that load release was carried out successfully (LED
Load rejection). When a message is received that the GLS has been closed the levels are reconnected
again in staggered fashion. Connection is completed when the final level has been activated or overload
occurs (evaluation optional). By staggering the connection, optimum load adjustment can be achieved for the
engine. The number of load levels is set when setting the general parameters.

When machine is idle or grid switch is closed, all load levels are reconnected.

Message: “Load release successful” all messages for individual levels are connected in sequence

Levels that have been entered with “0” delay time, are not switched off (not even in the case of
overload).

Load level contactors must be controlled so that contactors connect when couple relay is open. This
ensures consumer power is maintained by control unit in the case of a power failure or during repair
work.

Overload monitoring:
When the overload switch is activated (shaded green), power values are assigned to the individual levels.
When actual power value > (power value (current level) + overload limit), a delay period starts up. Once this
period has expired, a fault alarm is triggered (overload in grid standby operation) and one level is switched
off. This procedure is repeated until value is reduced again to below limit or the final level is switched off.
Levels are only reconnected when fault alarm has been acknowledged and value is below permitted limit.
When a load is so large that the module cuts out because of too low a frequency, the monitoring system also
ceases to work. Monitoring system also only checks next level has been connected if load has not exceeded
module capacity (e.g. 90%). In this case, a fault alarm is also sent out and the next level is not connected.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 25 von 94 24.01.2007


Parameters for load level control:
Delay (1-8) sec Level is only connected after delay time
has expired. Thereafter next delay time
starts and another level is connected.

Please note:
It is not possible to set several different
delay times (0, x, 0, …).
e.g.:
Level 1 = 0, Level 2 = 7, Level 3 = 0
In this case, all delay times will be
adjusted to default value. This will be
done automatically by the system.

Optional parameters for overload monitoring:


Power value % A maximum permissible value for power
is assigned to each level. Expected
power should not exceed this value.
If values entered exceed the 100%, a
default setting is made (30/30/30). This
is done automatically by the system.
Overload limit value % This value is added to the total power
value (sum of all active levels). If actual
power value does not exceed the value
calculated, a fault alarm is triggered
after overload delay period has expired
and the level is disconnected.
Overcharge delay sec When calculated limit value is
exceeded, the time delay period starts.
Once this time has expired, a fault
alarm is triggered - “overload in grid
standby” - and levels are disconnected
as described above.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 26 von 94 24.01.2007


Cosphi regulator (optional):

The Cosphi can be adjusted variably by the MMC. To do so, the Cosphi controller on the generator is
influenced by a motor potentiometer. The setpoint and the corresponding control parameters can be set via
the display.

Parameters for Cosphi control:


Release % The Cosphi controller is not enabled
until the electrical output is greater than
this limit value. Until this point, the plant
is run at the permanently set Cosphi
(set via the potentiometer on the
generator controller)
Setpoint The setpoint required is specified here.
The individual limits depend on the
generator.
Ki I proportion of the controller. The
greater the value, the faster the
controller becomes.
Tn sec Adjustment time of the controller. The
lower the value, the faster the controller
becomes.
Pause time ms The next adjustment pulse is output
after the pause time.
Pulse/pause time ms The adjustment pulse is output for the
adjustable time.
Starting position KOhm The preset Kohm setpoint determines
the Cosphi for the inactive Cosphi
controller (output < release limit value).
When the controller is enabled, the
motor potentiometer starts at this value.
The controller moves the motor
potentiometer to this setpoint every time
it is shut down.
Runtime ms The total runtime of the motor
potentiometer is set here.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 27 von 94 24.01.2007


Generator data

Press the Generator button to call up additional analog values from the generator.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 28 von 94 24.01.2007


5.10. Water System
This screen contains all sensors and drives for the hydraulic system. It is divided into two sections: “Heating
water and cooling water”. The various functions can be activated or deactivated. The pumps can be operated
manually.

You can also open the optional water temperature controller from this screen. To do so, press the regulation
valve.

Auxiliary drives:
The auxiliary drives start without delay on startup and run on for a set time after shutting down.

Parameters for the overtravel time of the auxiliary drives:


Overtravel time: min.

Preheating:
Module preheating allows the cooling water temperature to be kept within a set range.
Internal preheating via attached heating cartridges
The cooling water pump is also activated when preheating is activated.

Warm up gradient (cutoff value) – optional


Using this function, the power gradient is increased to an adjustable value after the GePS is activated.
The gradient is only continued if the cooling water temperature has also exceeded a set limit value.

Only active in automatic mode!

Parameter für Warmlauframpe:


Setpoint power % When the cutoff point for the setpoint gradient is
activated, the power setpoint stops at this setpoint until
the cooling water temperature IW has reached the
setpoint SW. The power setpoint is not increased further
until after this.
Cooling water motor °C The gradient is not continued until the set temperature is
reached.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 29 von 94 24.01.2007


5.11. Gas System
This screen gives an overview of the gas route.
The following gas system versions are available:
Single gas operation
Alternative gas operation with two gas routes
Alternative gas operation with one gas route

All necessary parameters and data are displayed or can be set. The optional gas condenser can be
accessed from this page and the gas leak test can also be activated at the appropriate level.

5.11.1. Alternative gas operation with two gas routes (optional)


Not enabled!!!

5.11.2. Alternative gas operation with just one gas route (optional)
Not enabled!!!

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 30 von 94 24.01.2007


5.12. Additional Function: Gas Compressor (optional)

The gas compressor is activated when a start request is received. After the switch-on delay time (time
required to build up gas pressure), the rest of the engine start process is released. The gas compressor
continues running after the engine is stopped. This time can be set.

Gas compressor parameters:


Switch-on delay sec The time that must expire before the motor can be
restarted.
Switch-off delay sec The gas compressor continues to run for this time.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 31 von 94 24.01.2007


5.13. Gas Leak Test

The gas leak test can be performed manually if the machine is idle. To do so, click the “Manual” button. The
button then turns orange. You can now initiate the test using the “Enable” button. All status indications can
be observed.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 32 von 94 24.01.2007


5.14. Oil System
This screen gives an overview of the lubricating oil supply. It is divided into three sections:

Lubricating oil refilling for the genset (standard)


Control for old oil pump
Controls for an (optional) fresh oil pump

Oil refilling:
Automatic oil refilling is activated by a request from the MTU motor management.

In order to bridge the reaction time between when the refilling solenoid valve opens and the oil level
monitor responds, the solenoid valve is actuated as follows. The solenoid valve is opened for the
opening time TO when the request is received from MTU motor management. It is subsequently closed
for the pause time TP. TO then begins again. This interplay is repeated until the MTU motor management
request is no longer pending.

See the oil refill counter for the number of requests from the MTU motor management.

Oil refilling parameters:


To sec Solenoid valve opening time
Tp sec Solenoid valve pause time

Old oil pump:


The old oil pump can be operated via the control. There are two ways of controlling the pump:
On-site operation via display
Activate manual button
Remote operation via key switch at heating cabinet

Functional description:
The old oil pump can be selected in the display. The following buttons are available:
Manual
Start/Stop

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 33 von 94 24.01.2007


Manual operation (press Manual button)
When Start is pressed, it pumps until the optional Old oil tank overfill or Old oil tank fill level > max contact is
activated or the pump is switched off manually.

Fresh oil pump (optional):


The fresh oil pump can be operated via the control. There are three ways of controlling the pump:
Automatic mode for oil refilling
On-site operation via display
Activate manual button
Remote operation via key switch at heating cabinet

Functional description:

Automatic mode for oil refilling:


The fresh oil pump is activated in the same intervals as the solenoid valve.

The fresh oil pump can be selected in the display. The following buttons are available:
Manual
Start/Stop

Manual operation (press Manual button)


When start is pressed, it pumps until the Level < min. contact is no longer pending on the refilling pump. The
filling pulse is then activated until the Level > max. contact from the motor oil tank or the optional Fresh oil
tank fill level < min. 2 contact is triggered. The pump can also be stopped manually.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 34 von 94 24.01.2007


5.15. Fault Alarm
This screen provides an overview of all pending fault alarms. You can also open the optional alarm log.
The log records all fault and operating alarms with times over an extended time. This facilitates analysis
of faults.

Functioning method:
The window opens automatically, when a new fault alarm occurs.
The corresponding combined alarm flashes in the menu bar when there is a new fault alarm (e.g. E flashes
red => there is a new emergency stop). Press the Reset Button to acknowledge fault alarms. When the fault
alarm is no longer pending, the text is cleared from the display. If a fault stops the machine is not reset it is
red otherwise yellow. If a less critical fault is not reset it is grey otherwise white. Press the Home Button to
exit the fault alarm window. The fault alarm window does not open again until a new fault alarm occurs or it is
selected via the E, S, A buttons.

The fault alarms are stored in a separate list. There are also some plant-specific alarms which
are displayed there. The list is printed for the relevant project.

There are two important groups of faults in the fault alarm overview. The first group consists of automatically
acknowledged faults. These faults are automatically reset and delete from the fault alarm overview after the
cause is rectified. The second group consists of faults which can only be reset after rectification when the
user presses the reset button (on the switching cabinet or the fault alarm page).

Fault alarms which activate the emergency stop chain can only be acknowledged with a hardware
reset (button on the MMC switching cabinet).

The source column only applies for multi-module plants and central fault histories, as it contains the module
numbers to indicate the module affected by the fault. If there are so many faults that they cannot all be
shown in the table, you can scroll up and down using the arrow keys right and left of the table.

The alarm log allows you to view faults which have already been rectified!

5.16. System Status Indications


This screen provides an overview of all pending status indications (cooling water pump on, generator switch
off, …). The screen layout is identical to that of the fault alarms. All active status indications are displayed
(highlighted in green). The optional alarm log can also be opened.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 35 von 94 24.01.2007


5.17. Alarm log

You can switch to the window that displays the fault history using the alarm log button in the fault alarm
window or system status indication window. When you switch to the alarm log page, the fault database is
searched and the occurrence and cessation of faults in previous 24 hours are displayed. If a fault has
stopped, the fault alarm is displayed along with “gegangen” (stopped).

The source column only applies for multi-module plants and central fault histories, as it contains the module
numbers to indicate the module affected by the fault. If not all the faults fit in the table, you can scroll up and
down using the arrow keys on the right side of the table.

Start button:
Use the Start button to begin a new search.

Filter button:
Use the filter button to open a selection window in which you can set the criteria for searching the database.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 36 von 94 24.01.2007


There are four filter criteria. If the colour changes to green, a criterion is active.

Message type:
You can select whether you want to list only the fault alarms (AM), only system status indications (SM) or
both message types (AM + SM). The default setting is fault alarm.

Kind:
You can select whether you want to display a fault occurrence, fault cessation or both. Both are indicated by
default.

Alarm number:
If you are only searching for the occurrence of a specific alarm, you can activate the alarm number search
using the Nb.-Search button. You must also enter the number you are searching for in the field below. You
can also select up to 4 numbers. Click Default to reset the number.

Days:
By default, the database search begins with the previous day. You can set the upper field to search the
database for older results. The highest value is 31 days. The value of the second field must always be 1. If
you are searching for results within a certain time period, for example, 10 and 20 days prior, you must also
change the value in the second field. The value of the second field must always be larger than the value in
the first field; however, the value cannot exceed 31.

Number:
The frequency of messages is determined. This evaluation is only intended for use by operators with a
higher user level.

Save button:
This buttons allows you to copy the current database to the D:\MDE\FileSharing directory, which is
accessible to customers.

Click Home to exit the alarm log window.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 37 von 94 24.01.2007


5.18. Power Controller
This screen gives an overview of the entire power controller. All important states and online data for the
power controller are displayed on the right.

Source of the setpoint:

The top line shows the operating state selected:

Local
Remote
Via interface (SS)
Manual operation
Timer

The corresponding LED illuminates and the valid operating mode (setpoint source) is highlighted in
green (e.g. flexible value).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 38 von 94 24.01.2007


Manual Operation:

The power setpoint can also be set manually. To do so, the key switch must be set to manual and
operation must be set to local. The “Manual” button lights orange after the key switch is switched. Now, a
“Manual value” can also be entered and subsequently confirmed by pressing OK. Set the key switch to
automatic to exit manual operation. The current valid setpoint is set again.

Parameters for manual operation:


Manual value % The value for manual operation set when the OK
key is pressed.

Setpoint depending on the current operating mode:

1 = Module off
2 = Flexible value
3 = Setpoint 1
4 = Setpoint 2
5 = Grid feed control
6 = Gas tank control
7 = CH4 control
8 = Current operation => fixed at 100%
9 = Heat operation
10 = Heat operation (floating)
11 = Heat operation (grid feed-in limit)
12 = Heating water reservoir operation => fixed at 100%

Local switching: The key switch must be set to Local. Press the corresponding button
(e.g. flexible value 1) to switch the operating mode.

Remote switching (hardware): To do this, a total of four digital inputs are available with which all
operating modes can be activated using the correct combination
(binary coding). Interface mode may not be active!

Switching via interface: The interface must be active and the corresponding data point must
contain the required number.

Switching using the timer: The switching is time-controlled (see timer description).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 39 von 94 24.01.2007


Valid setpoint:

Flexible value
Two values are displayed:
Local: This value applies when the “Controller” key switch is set to “Local”. The setpoint can be
entered directly.
Remote: This value applies when the “Controller” key switch is set to “Remote”. The setpoint is
specified via a 4-20mA signal. The value is determined via the telegram if an interface is used for
control.

Setpoint 1 (optional)
Two values are displayed:
Local: This value applies when the “Controller” key switch is set to “Local”. The setpoint can be
entered directly.
Remote: This value applies when the “Controller” key switch is set to “Remote”. The value (equals
the local value) stored in the program is requested via a digital input signal. The value is
determined via the telegram if an interface is used for control.

Setpoint 2 (optional)
Two values are displayed:
Local: This value applies when the “Controller” key switch is set to “Local”. The setpoint can be
entered directly.
Remote: This value applies when the “Controller” key switch is set to “Remote”. The value (equals
the local value) stored in the program is requested via a digital input signal. The value is
determined via the telegram if an interface is used for control.

Grid feed control (optional)


When the grid feed control mode is active, the current setpoint comes from the grid feed control (see
additional functions).

Gas Tank (optional)


When the gas tank mode is active, the current setpoint comes from the gas tank control (see additional
functions).

CH4 Regulation (optional)


When the CH4 control mode is active, the current setpoint comes from the CH4 control (see additional
functions).

Current operation (optional)


When the heating water reservoir mode is active, the setpoint is set to 100%.

Heat operation (optional)


When the heat operation mode is active, the current setpoint comes from the heating control (see
additional functions).

Heat operation floating (optional)


When the heat operation floating mode is active, the current setpoint comes from the heating control
(see additional functions).

Heat operation with grid feed-in limit (optional)


When the heat operation with grid feed-in limit mode is active, the current setpoint comes from the
heating control (see additional functions).

Heating water reservoir (optional)


When the heating water reservoir mode is active, the setpoint is set to 100%. The settings are
shown in the heating water reservoir operation (see additional functions).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 40 von 94 24.01.2007


Power reduction:
Displays whether power reduction is active. Reduction can be triggered by various factors:

Knocking signal
The MTU motor management reduces power by knocking. This kind of reduction is indicated.

Gas change (optional)


Power is reduced to a set value during the gas change. This value may even fall below the minimum load of
the module.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 41 von 94 24.01.2007


5.19. Start / Stop Procedure

The start or stop procedure can be observed in this screen. The individual start phases are activated when
the module starts. Manual operation can also be implemented from this page.

Manual Operation:
Key switch set to Local

Key switch set to Manual

Activate start request locally (switch)

The engine starts and stops at phase 3 (synchronization not initiated)

In the idle state, the speed can now be adjusted locally using the higher / lower keys

Press the Synchronization button to start synchronization. Synchronization must also be enabled by
MTU motor management (digital input signal)

The power can be preset when the generator switch is closed. It is automatically set to 10% on
activation. There are two ways of changing the power:
Using the higher / lower keys and the corresponding typing value.
Using a manually entered setpoint and the OK key.
Parameters for manual operation:
Typing value % The setpoint is changed by the typing value every
time an arrow key is pressed.
Manual value % The value for manual operation set when the OK
key is pressed.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 42 von 94 24.01.2007


5.20. Counter reading

Some of the counter readings are optional (gas quantity, current counter, heat quantity, steam, reserve).
These counters are evaluated using a pulse signal. The pulse value is cumulated for each pulse. This is set
in the module parameters.
Setting the counter readings
You can enter a desired counter reading value using the “Setpoint” input field. When you press the “Reset
Button” of a counter, the entered value is changed to the current counter reading for this counter.

The following page is opened when you press the Backup button:

A backup of the previous 365 days with the date for the most important operating values is stored.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 43 von 94 24.01.2007


5.21. Overview of Auxiliary Features

Use the corresponding buttons as in the main menu to call up the individual sub-functions. Unavailable
functions are grayed out and cannot be selected.

5.22. Cleaning Window

The screen can be cleaned easily when this screen is open, as no operating elements are displayed.
Only one element (home button) changes the display.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 44 von 94 24.01.2007


5.23. Additional Function: Water Temperature Controller (optional)

The controller is a PI controller whose initial size can be set by the regulation valve from fully closed (0%) to
fully open (100%).

Control reaction:
Actual value > Setpoint => The control valve closes (until the minimum opening permitted at most).

Direction:
However, if the control valve does not match this direction, you can change the setting via a module
parameter.

Two types of actuator can be used for the temperature controller:

Analog actuator (standard: 0 to 10V)


Actuator with open/closed pulses (with limit positions)

Manual operation can be used for both actuators. Manual operation is reset when the module is
restarted.

Special feature of actuators with open/closed pulses and limit positions:


Each time the overtravel time elapses, a reference stroke is initiated. This allows the runtime of the valve
to be determined and the setting position of the control valve can always be determined via the
pulse/pause ratio. The reference stroke can also be activated manually using the “Start reference stroke”
button in the idle state. Reference strokes cannot be cancelled once they have been started.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 45 von 94 24.01.2007


Temperature controller parameters:
Setpoint °C This parameter is the same as the setpoint for the controller. After the
start-up gradient, the controller adjusts the temperature to this value.
Starting °C The start gradient (for the temperature) is started from this value.
setpoint
Warm-up time sec The start gradient is increased from the start setpoint to the actual
setpoint over this time.
Overtravel time sec When the controller is deactivated, there is an overtravel time.
KP Proportional share of the controller. Per °C deviation, the variable is
opened or closed by this factor (e.g. standard deviation +5°C, KP=6=>
Proportional share of the variable is 30%.).
The KP can be set differently for normal operation and the warm-up
time!
Ki Integral share of the controller. If standard deviation remains, the Ki value
is added to the P share every time the adjustment time (Tn) expires. A
large Ki value can cause the setting for the regulation valve to fluctuate.
Tn sec The adjustment time serves to calculate the I proportion.
The starting value of the I controller is added to the starting value of the P
controller in these time intervals. An inadequate adjustment time can
cause the setting for the regulation valve to fluctuate.
The Tn can be set differently for normal operation and the warm-up
time!
Permitted % When running, the valve can only be closed or opened (depending on the
opening direction) to the angle of opening entered here.
Manual % When manual operation is active, this setpoint is output to the regulation
correcting valve.
variable

Additional parameters for three-level controllers:


Pulse/pause ms A pulse (open or close) is sent for the time set. The same pause time
time elapses after each pulse.

For example, if you have a valve with a running time of 130 seconds
(from open to closed) and you set a time of 1300ms, then a correcting
variable change of 1% per pulse would result. The running time is
determined by a reference stroke for regulation valves with limit positions.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 46 von 94 24.01.2007


5.24. Additional Function: Mixture Water Controller (optional)
This function allows you to adjust the mixture water for the engine to a defined setpoint.

Control reaction:
Actual value > Setpoint => The control valve opens (until the permitted opening set at most).

This controller functions in the same way as the water temperature controller.

5.25. Additional Function: Mixture fan and pump (optional)


This function cools the mixture water (re-cooler).

Version 1: Cooler via level switching:

The number of existing levels is determined by a module parameter. A maximum of 2 levels are
available. A level is only one switching point. This can also mean that a star/triangle-connected fan is set
up with two levels. You can switch between the individual levels using the arrow keys. The current
parameters are displayed for the selected level (no.).
If a level is running, a green LED illuminates. Each level can also be operated manually. Manual
operation is indicated by an illuminated orange LED.
The function of each individual level can be defined using the following four parameters.

Parameters for re-cooler levels:


Startup value °C When the actual temperature value exceeds this limit, the
cooler level is activated after the switch on delay.
Switch on delay sec Switch on delay for the cooler level.
Shutdown value °C When the actual temperature value falls below this limit, the
cooler level is deactivated after the switch off delay.
Switch off delay sec Switch off delay for the cooler level.

Pump:
The mixing pump is activated immediately with auxiliary drives. The pump can also be operated
manually when idle.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 47 von 94 24.01.2007


Version 2: Cooler via frequency converter:

In progress!!!

In this version, the re-cooler fans are controlled via a frequency converter. A PI controller is used for this to
output the setpoint (0-10V) to the frequency converter. The setpoint can otherwise only be set manually.

Parameters for frequency converters:


The control parameters of the PI controller are identical to those of the water temperature controller.
However, there are no warm-up and overtravel times.

Pump:
The mixing pump is activated immediately on activation of the auxiliary drives. The pump can also be
operated manually when idle.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 48 von 94 24.01.2007


5.26. Additional Function: Emergency Cooling Water Controller (optional)
This function allows you to adjust the coolant circuit for the engine to a defined setpoint.

Control reaction:
Actual value > Setpoint => The control valve opens (until the permitted opening set at most).

This controller functions in the same way as the water temperature controller.

5.27. Additional Function: Emergency cooler fan and pump (optional)


Version 1: Emergency cooler fan via level switching

Emergency cooler fan:


The number of existing levels is determined by the option parameters. A maximum of 12 levels are
available. A level is only one switching point. This can also mean that a star/triangle-connected fan is set
up with two levels. You can switch between the individual levels using the arrow keys. The current
parameters are displayed for the selected level (no.).
If a level is running, a green LED illuminates. Each level can also be operated manually. Manual
operation is indicated by an illuminated orange LED.
The function of each individual level can be defined using the following four parameters.

Parameters for emergency cooler levels:


Startup value °C When the actual temperature value exceeds this limit, the
emergency cooler level is activated after the switch on delay.
Switch on delay sec Switch on delay for the emergency cooler level.
Shutdown value °C When the actual temperature value falls below this limit, the
emergency cooler level is deactivated after the switch off delay.
Switch off delay sec Switch off delay for the emergency cooler level.

Emergency cooler pump:


The emergency cooler pump can also be set with a series of parameters like the fan levels. The pump
can also be operated manually.

Parameters for emergency cooler pump:


Startup value °C When the actual temperature value exceeds this limit,
the pump is activated after the switch on delay.
Switch on delay sec Switch on delay for the pump.
Shutdown value °C When the actual temperature value falls below this limit,
the pump is deactivated after the switch on delay.
Switch off delay sec Switch off delay for the pump.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 49 von 94 24.01.2007


Version 2: Emergency cooler fan via frequency converter:

In this version, the emergency cooler fans are controlled via a frequency converter. Up to 2 frequency
converters can be used. One PI controller is used for each to output the setpoint (0-10V) to the frequency
converter. The setpoint can otherwise only be set manually. However, if 2 frequency converters are used,
there is only one setpoint!

Parameters for frequency converters:


Setpoint °C This parameter is the same as the setpoint for the controller.
Startup value % or °C When the limit value is reached, the frequency converter is enabled.
System dependent: e.g. activation via the position of an emergency
cooling control valve (%) or based on the water temperature (°C).

If 2 frequency converters are used, the second FC is enabled based


on the correcting variable of the first FC!
Shutdown °C If the value falls below the limit, the frequency converter is deactivated.
value
Relief value % When the frequency converter is deactivated, this value is passed to the
emergency cooling valve as a setpoint. This is to smooth the switching
process.

If 2 frequency converters are used, this value is assigned to the first


FC as a correcting variable!
KP Proportional share of the controller. Per °C of deviation, the correcting
variable is increased or decreased by this factor (e.g. standard deviation
+5°C, KP=6=> Proportional share of the variable is 30%).
Ki Integral share of the controller. If standard deviation remains, the Ki value
is added to the P share every time the adjustment time (Tn) expires. A
large Ki value can cause the setting for the frequency converter to
fluctuate.
Tn sec The adjustment time serves to calculate the I proportion.
The starting value of the I controller is added to the starting value of the P
controller in these time intervals. An inadequate adjustment time can
cause the setting for the frequency converter to fluctuate.
Manual % When manual operation is active, this setpoint is output to the frequency
correcting converter.
variable

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 50 von 94 24.01.2007


5.28. Additional Function: Room Temperature Controller (optional)
This function allows you to adjust the room temperature to a defined setpoint. The flap control (incoming air,
outgoing air, circulation air) must be wired to the hardware so one input signal (e.g. 0 to 10V) adjusts all flaps
to the correct position.

Control reaction:
Actual value > Setpoint => The control valve opens (until the permitted opening set at most).

This controller functions in the same way as the water temperature controller.

5.29. Additional Function: Room Air Fan Control (optional)


Version 1: Room fan via level switching:

The number of existing levels is determined by a module parameter. Up to 4 levels are available
(incoming and outgoing air). A level is only one switching point. This can also mean that a star/triangle-
connected fan is set up with two levels. You can switch between the individual levels using the arrow
keys. The current parameters are displayed for the selected level (no.). If a level is running, a green LED
illuminates. Each level can also be operated manually. Manual operation is indicated by an illuminated
orange LED.
The function of each individual level can be defined using the following four parameters.

Parameters for room air fan levels:


Startup value °C When the actual temperature value exceeds this limit, the room
air fan level is activated after the switch on delay.
Switch on delay sec Switch on delay for the room air fan level.
Shutdown value °C When the actual temperature value falls below this limit, the
room air fan level is deactivated after the switch off delay.
Switch off delay sec Switch off delay for the room air fan level.

If the fan is activated by a thermostat (e.g. 2 level), the parameters have no function.
Optional: All fan levels are always activated if there is a gas pre-alarm. The fans are deactivated for
main gas alarms.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 51 von 94 24.01.2007


Activation of the room fan (adjustable):

The "Enable room fan" button allows the fans to be enabled as required.

The following combinations are possible:

Enable even when the system is idle =>


The fans are switched on when the value exceeds the limit even if the machine is idle.

Enable only when the system is running =>


The fans are only enabled when the machine is running and the value exceeds the limit.

Level 1 immediately on operation =>


This option can also be activated in addition to the two versions specified above. The first fan level is then
activated immediately when the motor is started (regardless of the limit value).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 52 von 94 24.01.2007


Version 2: Room fan via frequency converter:

In this version, the room fans (incoming / outgoing air) are controlled via a frequency converter. One PI
controller is used for each to output the setpoint (0-10V) to the frequency converter. The setpoint can
otherwise only be set manually.

Parameters for frequency converters:


Setpoint °C This parameter is the same as the setpoint for the controller.
Idle state offset °C When the machine is idle, this value is added to the setpoint. This
prevents constant activation/deactivation when idle, while still dissipating
built-up heat.
Startup value °C This value is added to the setpoint. If the room temperature exceeds the
limit value, the FC is enabled.
Shutdown °C This value is subtracted from the setpoint. If the room temperature is less
value than the total value, the FC is deactivated again.
KP Proportional share of the controller. Per °C of deviation, the correcting
variable is increased or decreased by this factor (e.g. standard deviation
+5°C, KP=6=> Proportional share of the variable is 30%.).
Ki Integral share of the controller. If standard deviation remains, the Ki value
is added to the P share every time the adjustment time (Tn) expires. A
large Ki value can cause the setting for the frequency converter to
fluctuate.
Tn sec The adjustment time serves to calculate the I proportion.
The starting value of the I controller is added to the starting value of the P
controller in these time intervals. An inadequate adjustment time can
cause the setting for the frequency converter to fluctuate.
Permitted % In operation, the correcting variable output cannot be less than this value.
opening
Manual % When manual operation is active, this setpoint is output to the frequency
correcting converter.
variable

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 53 von 94 24.01.2007


5.30. Additional Function: CH4 Regulation (optional)

The CH4 controller is divided into several sections:

Start release of the engine based on the CH4 content (digital contact or limit value via analog actual
value signal).
Power limitation based on the CH4 content (only works if an analog actual value signal is available)

All functions are only active in automatic operation!

Start release via digital contact:


This module is released or blocked depending on the CH4 content. To do so, a digital sensor is queried.
The following parameters are made available:

Switch on delay sec When the contact is triggered, this time elapses. The module is not
released until this time has elapsed and the corresponding signal is
received.
Switch off delay sec When the contact is deactivated, this time elapses. The module is
not blocked until this time has elapsed and the corresponding
signal is received.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 54 von 94 24.01.2007


Start release via analog signal - optional:
This module is released or blocked depending on the CH4 content. An analog actual value signal is queried
and compared with the limit values. The following parameters are made available:

Switch on CH4 % The switch on timer starts when the actual value exceeds this limit.
content
Switch on delay sec This time elapses when the value exceeds the limit. The module is
not released until this time has elapsed and the limit value is
exceeded.
Switch off CH4 % The switch on timer starts when the actual value falls below this
content limit.
Switch off delay sec This time elapses when the value falls below the limit. The module
is not blocked until this time has elapsed and the value falls below
the limit.

The customer must determine the curve.


Power limitation via analog signal:
The power of the engine is limited based on the CH4 content. An analog actual value signal is queried and
compared with the limit values. The following parameters are made available:

Min. at CH4 content % The lowest power level is assigned to this CH4 value.
Power at min. % The power is limited to this value when the CH4 value falls below
the min. limit. The limit is calculated via a straight line between the
minimum and maximum value.
Max. at CH4 content % The highest power level is assigned to this CH4 value.
Power at max. % The power is limited to this value when the CH4 value exceeds the
max. limit. The limit is calculated via a straight line between the
minimum and maximum value.

Values can only be modified from a certain user level (service).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 55 von 94 24.01.2007


5.31. Gas Tank (optional)

The gas tank controller is divided into several sections:

Start release of the engine based on the fill level/gas pressure (digital contact or limit value using an
analog actual value signal)
Power limitation based on the fill level/gas pressure (digital contact or limit value using an analog
actual value signal)

All functions are active in automatic operation only.

The evaluation is carried out either via an analog signal (standard) or digital signals (3 contacts). A
combination is not useful and therefore not possible!

The customer must determine all parameters.

Gas tank (fill level/pressure): Start release using a digital contact:


This module is released or blocked depending on the fill level/pressure. Two digital sensors are queried.
The following parameters are available:

Switch-on delay sec When the contact is triggered, this time elapses. Once this time
elapses, the module is released and the corresponding signal
is received.
Switch-off delay sec When the contact is triggered, this time elapses. Once this time
elapses, the module is blocked and the corresponding signal is
received

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 56 von 94 24.01.2007


Gas tank (fill level/pressure): Start release using an analog signal:
This module is released or blocked depending on the fill level/pressure. An analog actual value signal is
queried and compared with the limit values. The following parameters are available:

Startup value % The switch-on timer starts when the actual value exceeds this
limit.
Switch-on delay sec This time elapses when the value exceeds the limit. Once this
time elapses, the module is released and the limit value is
exceeded.
Shutdown value % The switch-on timer starts when the actual value falls below
this limit.
Switch-off delay sec This time elapses when the value falls below the limit. Once
this time elapses, the module is blocked and the value falls
below the limit.

Gas tank (fill level/pressure): Power limitation using digital contacts


Engine power is limited based on the fill level/pressure. To do so, a third switch is read (off, on & max. power
value, min. power value).
The following parameters are available:

Power at max. % When the switch is triggered (on & max. power value), the
power is set to this setpoint.
Power at min. % When the switch is triggered (min. power value) and the on &
max. power value switch is not active), the power is set to this
setpoint.

Gas tank (fill level/pressure): Power limitation using an analog signal:


Engine power is limited based on the fill level/pressure. An analog actual value signal is queried and
compared with the limit values. The following parameters are available:
Min. fill level/pressure at % The lowest value of the power value is assigned to this fill
level/pressure value.
Power at min. % If the fill level/pressure falls below the min. limit, the power is
limited to this value. The limit is calculated using a straight line
between the minimum and maximum value.
Max. fill level/pressure % The highest power value is assigned to this fill level/pressure
at value.
Power at max. % If the fill level/pressure exceeds the max limit, the power is
limited to this value. The limit is calculated using a straight line
between the minimum and maximum value.

Gas tank (fill level/pressure): Torch release using an analog signal:


The torch is released or blocked depending on the fill level/pressure. An analog actual value signal is queried
and compared with the limit values. The following parameters are available:
Startup value % The switch-on timer starts when the actual value exceeds this
limit.
Switch-on delay sec This time elapses when the value exceeds the limit. Once this
time elapses, the torch is released and the limit value is
exceeded.
Shutdown value % The switch-on timer starts when the actual value falls below
this limit.
Switch-off delay sec This time elapses when the value falls below the limit. Once
this time elapses, the torch is blocked and the value falls below
the limit.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 57 von 94 24.01.2007


5.32. Grid feed control (optional)

There are three ways of controlling the grid transfer power:

Plant draws power from grid.


Plant supplies power to grid.
The load is regulated to zero at the grid transfer station (no-load regulation).

The actual value signal at the grid transfer station is a “+/- signal” (e.g. -2000 kW to +2000 kW).
The signal is evaluated as follows:

Generator power < consumer power => signal is positive (+) => plant draws power from grid
Generator power > consumer power => signal is negative (-) => plant supplies power to grid
Generator power = consumer power => signal is zero => plant neither draws power from grid nor
supplies power to grid

One can also set a start release of the module based on the grid transfer power. The engine is only released
when the configurable switch on threshold has been exceeded. The same applies to the switch off threshold.
This allows the system to be used ideally, so that no peak currents must be paid for.

All functions are active in automatic operation only!

When using the two functions (grid feed control and start release), you must ensure that they do not
cancel each other out (e.g. the grid feed control is set to adjust to a value which is evaluated as a
deselection point of the system).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 58 von 94 24.01.2007


Status indications:
No-load regulation active.
This indicates when grid feed control is activated.
Plant supplying to grid.
This indicates when the plant is supplying to the grid.
Plant drawing from grid.
This indicates when the plant is drawing from the grid.
Controller dead zone active
This indicates when the deviation is less than the dead zone.
Maximum setpoint reached
This indicates when the setpoint calculated has reached the maximum permitted setpoint for the power
controller. The maximum setpoint (%) is shown in the power controller parameters. The setpoint is
specified in the module parameters and cannot be changed.
Minimum setpoint reached
This indicates when the setpoint calculated has reached the minimum permitted setpoint for the power
controller. The minimum setpoint (%) is shown in the power controller parameters. The setpoint is
specified in the module parameters and cannot be changed.
Start release

If the setpoint/actual value deviation is negative, the plant supplies power to the grid. If the deviation is
positive, the plant draws power from the grid.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 59 von 94 24.01.2007


Parameter for the grid feed control:
Setpoint KW The power is adjusted to this value at the grid transfer station. If the value is
negative, the plant must supply power to the grid.
Dead zone KW If the deviation (xd) is less than this value, the setpoint for the power controller is
not changed. This prevents the system fluctuating.
Increment KW This value specifies how many percent the setpoint for the power controller is
changed each second. The setpoint for the power controller is only changed if the
deviation is greater than the dead zone. The increment value set must be less
than the dead zone value.
Pause time sec This is the pause time between two changes of the setpoint for the power
controller.

Parameters for start release:


X1 KW Selection without delay. The engine is released immediately when
the actual value exceeds this limit.
X2 KW Delayed selection. The engine is released after a delay time when
the actual value exceeds this limit and is less than the switch on
without delay value. The delay time is calculated on a straight line
between the undelayed and delayed switch on value.
Y1 sec Delay time for the selection. This time is calculated on a straight
line between the undelayed and delayed switch on value.
The closer the current actual value is to the switch on without delay
value, the shorter the delay time.
X3 KW Delayed deselection. The engine is blocked after a delay time
when the actual value falls below this limit. The delay time is
calculated on a straight line between the undelayed and delayed
switch off value.
X4 KW Deselection without delay. The engine is blocked immediately
when the actual value falls below this limit.
Y2 sec Delay time for deselection. This time is calculated on a straight line
between the undelayed and delayed switch off value. The closer
the current actual value is to the switch off without delay value, the
shorter the delay time.

The limit values for selection/deselection must decrease from left to right (on the x-axis). If this is not
observed, a default value is activated (+400, +300, -300, -400).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 60 von 94 24.01.2007


5.33. Exhaust / Bypass Butterfly Valve Control (optional)

The exhaust flap is opened when the module starts. It is required for multi-module plants to prevent back-
flows of combustion air into the deselected modules.

The bypass flap is intended to channel the hot exhaust gas past the exhaust gas heat exchanger with little
heat absorption to prevent the heating water overheating. Bypass operation can be activated via a
configurable limit value or manually using the selection button. Bypass operation can also be activated
remotely via an optional input. Flap 2 is opened, and flap 1 is closed after the “Open” limit switch is triggered.

All flaps can also be operated manually.

Parameters for bypass operation:


Bypass operation limit value °C When the value exceeds the limit, bypass flap 2 opens and
then bypass flap 1 closes.
Hysteresis for bypass °C When the value falls below the limit by the hysteresis,
operation: bypass operation is deactivated.

All functions are active in automatic operation only!

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 61 von 94 24.01.2007


5.34. Heat operation motor (optional)
Start release is based on a water temperature only:

The module is stopped or started automatically when the temperature exceeds/falls below various limits.
Delay times can also be entered. All limit values can also be shifted via the external temperature or a
reduction.

All functions are active in automatic operation only!

Parameters for a stat request:


Selection without delay °C The engine is released immediately when the actual value falls
X1 below this limit.
Delayed selection °C The engine is released after a delay time when the actual value
X2 falls below this limit and is greater than the switch on without
delay value. The delay time is calculated on a straight line
between the undelayed and delayed switch on value.
Delay time for the sec This time is calculated on a straight line between the undelayed
selection and delayed switch on value. The closer the current actual value
Y1 is to the switch on without delay value, the shorter the delay time.
Deselection without delay °C The engine is blocked immediately when the actual value
X4 exceeds this limit.
Delayed deselection °C The engine is blocked after a delay time when the actual value
X3 exceeds this limit and is less than the without delay limit value.
The delay time is calculated on a straight line between the
undelayed and delayed switch off value.
Delay time for deselection sec This time is calculated on a straight line between the undelayed
Y2 and delayed switch off value. The closer the current actual value
is to the switch off without delay value, the shorter the delay time.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 62 von 94 24.01.2007


Floating: Start release and output control are based on a water temperature:

The controller is a PI controller whose initial size can be changed by the output of the module from 50%
(min. setpoint) to 100%.

The limit values for the start release can be influenced using the external temperature curve.

All functions are active in automatic operation only.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 63 von 94 24.01.2007


Example with heating water return flow temperature as the setpoint variable:

Start release (value correspond to the current illustration above):


If the module is idle and the heating water return flow temperature (actual value) drops below 66°C (X2 in
illustration), then the module is activated after 30 seconds (Y2 in illustration). The more the temperature
drops (direction X1), the faster the module is activated.

Controller (value correspond to the current illustration above):


If the module is running, the setpoint power is determined based on the heating water return flow
temperature in the PI control. The current actual temperature value is also displayed. An attempt is made to
adjust the heating water return flow temperature to the “Setpoint” (70°C in the example), i.e. until the heating
water actual value is less than the heating water setpoint; the module power setpoint (setpoint power) is
increased according to the controller parameters (up to max. 100%). If the heating water actual value
exceeds the heating water setpoint, the module power setpoint is reduced again (to setpoint min).

Special “Heat operation with limit function” feature:


In this mode, the calculated setpoint is limited by the grid feed control. Unlike the current calculated setpoint
of the grid feed control, the setpoint is not increased further.

Shutting down (start release is deactivated):


When the heat controller registers the “Setpoint min” and the “Heating water temperature > limit value 1” fault
alarm is pending, the module is deactivated. This results in the longest possible service life of the module.

Displaying the output control

Control active This LED turns green as soon as the control has been activated (start
release active through heat operation and grid parallel operation).
Warm-up time This LED turns green while the start-up gradient is active and the warm-
up time expires
Setpoint min This LED turns green as soon as the calculated module setpoint power
equals the "Setpoint min".
100% This LED turns green as soon as the calculated module setpoint power
equals the setpoint max and 100%.
Grid feed control If no grid feed control is present, this display is deactivated.
During limited heat operation, this LED turns green as soon as the output
of the grid feed control is less than the output of the floating heat
operation. Below the LED, the calculated output of the grid feed control is
also displayed.
Setpoint °C The current heating water temperature setpoint is displayed here. The
heating water temperature is increased from the start setpoint to the
setpoint during the warm-up time.
Actual value °C The current actual value for the heating water temperature is displayed
on the temperature sensor.
Setpoint/actual °C The difference between the setpoint and the actual value is displayed
value deviation here (setpoint – actual value).
Deviation
Setpoint power % The module setpoint power is displayed here.
Actual value % The module actual power value is displayed here.
power

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 64 von 94 24.01.2007


Parameters for output control:
Setpoint °C This parameter is the same as the controller setpoint (heating water
temperature). After the start-up gradient, the controller adjusts the
heating water temperature to this value via the module output.
Start setpoint °C Once the controller is activated, the setpoint temperature is increased by
one start-up gradient. This setpoint gradient (for the temperature setpoint)
is started from this value.
Warm-up time sec The temperature setpoint is increased from the start setpoint to the actual
setpoint during the warm-up time. This means that after this time has
expired, the entered “setpoint” is adjusted to the temperature value.
KP Proportional share of the controller. Per °C deviation, the variable
(module power setpoint) is opened or closed by this factor (e.g. standard
deviation +5°C, KP=6=> Proportional share of the variable is 30%.).
Ki Integral share of the controller. If standard deviation remains, the Ki value
is added to the P share every time the adjustment time (Tn) expires. A
large Ki value can cause the setting for the module power to fluctuate.
Tn sec The adjustment time serves to calculate the I proportion.
The starting value of the I controller is added to the starting value of the P
controller in these time intervals. An inadequate adjustment time can
cause the setting for the module power to fluctuate.
Setpoint min % Equals the minimum power upon which the module can be operated

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 65 von 94 24.01.2007


5.35. Heat operation boiler (optional)

The boiler is stopped or started automatically when the temperature exceeds/falls below various limits. Delay
times can also be entered. All limit values can also be shifted via the external temperature or a reduction.

All functions are active in automatic operation only!

Parameters for a stat request:


Selection without delay °C The boiler is released immediately when the actual value falls
X1 below this limit.
Delayed selection °C The boiler is released after a delay time when the actual value
X2 falls below this limit and is greater than the switch on without
delay value. The delay time is calculated on a straight line
between the undelayed and delayed switch on value.
Delay time for the sec This time is calculated on a straight line between the undelayed
selection and delayed switch on value. The closer the current actual value
Y1 is to the switch on without delay value, the shorter the delay time.
Deselection without delay °C The boiler is blocked immediately when the actual value exceeds
X4 this limit.
Delayed deselection °C The boiler is blocked after a delay time when the actual value
X3 exceeds this limit and is less than the without delay limit value.
The delay time is calculated on a straight line between the
undelayed and delayed switch off value.
Delay time for deselection sec This time is calculated on a straight line between the undelayed
Y2 and delayed switch off value. The closer the current actual value
is to the switch off without delay value, the shorter the delay time.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 66 von 94 24.01.2007


5.36. External temperature shift (optional)
The external temperature shift can be used for the heating operation (motor and boiler). This function
influences the switching point for the release.

An offset (positive or negative) is calculated via the curve using the current external temperature, which is
then added to the switching points. The shift can be adjusted for conditions via three gradients. 4 sets of
parameters are required for this.

The limit values for the x-axis (external temperature limit values) must increase from left to right.
The limit values for the y-axis (offset limit values) must increase from top to bottom.

The switching points can also be shifted down by a set value via a decrease (activated via an optional input).

Parameters for the external temperature:


X1 °C External temperature value for offset value Y1
Y1 °C Offset value for external temperature value X1
X2 °C External temperature value for offset value Y2
Y2 °C Offset value for external temperature value X2
X3 °C External temperature value for offset value Y3
Y3 °C Offset value for external temperature value X3
X4 °C External temperature value for offset value Y4
Y4 °C Offset value for external temperature value X4

Parameter for decrease:


Decrease value °C All switching points are shifted downward by this value.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 67 von 94 24.01.2007


5.37. Heating Water Reservoir (optional)

The module is started or stopped by a water reservoir controller.


For this, 4 sensors in the water reservoir are evaluated. This screen shows whether the buffer is being filled
or emptied. A set heat-up time begins when the module is released for startup. After this timer has elapsed,
further heat generators (e.g. boiler) are released for activation.
However, if the gradient evaluation system detects that the buffer is already being refilled, no other heat
generators can be selected.

All functions are active in automatic operation only!

Parameters for the water reservoir:


PT4: Selection without delay °C The engine is released immediately when the actual value
falls below this limit. The reservoir is empty.
PT5: Delayed selection °C The engine is released after a delay time when the actual
value falls below this limit (see delay time).
PT5: Delay time for the sec This timer starts when the value for PT5 falls below the
selection limit. The engine is released after the timer has elapsed.
PT7: Deselection without °C The engine is blocked immediately when the actual value
delay exceeds this limit. The reservoir is full.
PT6: Delayed deselection °C The engine is blocked after a delay time when the actual
value exceeds this limit and is less than the limit value for
PT7 (see delay time).
PT6: Delay time for sec This timer starts when the value for PT6 exceeds the limit.
deselection The engine is blocked after the timer has elapsed.
Warm-up time min. Further heat generators can be released after the warm-up
time has elapsed.

Parameters for the gradient:


Time °C Time in which between a temperature difference has been
measured to see if the reservoir is filled or emptied. If the
reservoir is filled no more heat generator is released
Temperature sec Temperature difference which has to be recognized to see
if the reservoir is filled or emptied.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 68 von 94 24.01.2007


5.38. Additional Function: Timer (optional)
The operating characteristics of the system can be influenced at certain times of the day or weekdays using
the timer.

A maximum of 5 operating modes can be activated on a system!

Operation:

In the top half of the menu, you can see the weekdays with the currently set operating modes at certain
times of day. The various operating modes are displayed in colour. A maximum of 8 switching points can be
set per day. Below the weekdays, you can see the key of the available operating modes. At the very bottom
right side, you can see the current operating mode.

You can select the following functions using the three buttons below on the left:
1. Time program: The timer controls the operating modes of the system.
2. Always on: The timer program is deactivated. The module is always released.
3. Always off: The timer program is deactivated. The module is blocked.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 69 von 94 24.01.2007


Setting a switching point for a weekday:

To set a switching point, you must click the bar of the desired weekday. An entry window opens.

On the left side, you can see the activated switching points with the corresponding selected operation mode.

Deleting a switching point:


If you would like to delete a switching point, press “Delete”.

Adding a switching point (max. 8):


To enter a new switching point, you must click “h” and “min”. Then click the corresponding Operating mode
(colour keys) and “Accept”. This is how you add the required switching point for the day.

To activate the set value, press “Save!”. The button is only active if the data has been changed.

To reach the overview again, click in the middle of the screen.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 70 von 94 24.01.2007


5.39. Additional Functions: SMS/e-mail (optional)
This function allows you to send a message by e-mail should faults or system status indications occur.
These e-mails accumulate on the MDE server and are then forwarded to the entered customer addresses.
The automatic maintenance request can also be indicated.

When transferring messages by e-mail, all currently active messages are summarised and sent per
e-mail. All active messages are individually sent to the SMS recipients (due to character lengths).
You should therefore be very careful when selecting the messages to be sent (also due to
accumulating costs).

Requirements:

See separate document: "Message service technical description"

Transferring operating data (optional additional function):


Once a day, the most important operating data (e.g. operating hours, startup counter, miscellaneous counter
statuses, overview of the cumulative fault alarms, etc.) are automatically sent via MDE per e-mail.

The operating data cannot be transferred per SMS, since the text document is considerably long!

Operation: Overview window

The first text field in the overview window displays the collected SMS messages to be sent, and the second
text field displays the messages to be sent per e-mail. The third text field records the send status. If the
pending messages are processed and sent, they are deleted from the first two text fields. This also occurs
when messages cannot be sent, for example, when remote data transmission to the Internet provider cannot
be established. Successful and failed send attempts are also recorded in the status window. This window is
deleted every day at midnight. The buttons at the lower end of the overview window allow you to configure
the SMS/e-mail client.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 71 von 94 24.01.2007


Operation: Selecting system status indications for notification

Click the system status indication button in the overview window to open the page where you can set
message options for system status indications. In the first column, you can see whether or not the
corresponding system status indication is selected for notification by SMS. If the message is selected, the
box is highlighted in green and Yes is displayed. When messages are not selected, the corresponding box is
white and No is displayed. In the second column, you can select the corresponding system status indication
to be sent by e-mail. To change your selection, select the corresponding box. You can only make changes if
you have logged into the main operation menu.
Use the four buttons on the right table margin to move the contents of the table up and down to process all
the messages.

Operation: Selecting fault alarms for notification


See selecting the system status indications!

5.40. Service menu

This menu is intended for service purposes only. The menu can only be opened by authorized
personnel.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 72 von 94 24.01.2007


5.41. External Communication (optional)

The active communication protocol is indicated. The current status of communication is also displayed.
This can be helpful when troubleshooting.
The parameter window opens when you click the active communication protocol (e.g. Modbus).

All parameters used are shown in this window. This window allows you to change the address, for example.
Press the “Save” button to activate the data.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 73 von 94 24.01.2007


You can open a simulation window for testing. To do so, press the “Simulation” button.

When activated, the simulation intervenes directly with the data transfer between the MMC and the
connected remote control.

Press the “Active” button to start the simulation. The data areas from the controller selected for simulation
are replaced with the data selected in the simulation window.

Attention:
Once testing is completed, the simulation must be deactivated using the “Active” button.
After 120 minutes, the simulation is automatically switched off.

Simulation of output data => data sent to the external interface (status)

Select the bit information to be simulated using the interface description


Enter status no. required (e.g. fault alarms 1-16)
Set or reset the required bits (e.g. set fault alarm 7)
Tests can be carried out at the remote station to determine whether the signal is received correctly

When simulating analog values, the status number of the value required (see interface description) must also
be entered. You can then enter the simulation setpoint.

Checking the input data => data received by the external interface (controls)

If the data received by the MMC is to be tested, only the control number must be entered. The corresponding
bit pattern or the equivalent analog value is then displayed.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 74 von 94 24.01.2007


5.41.1. Interface protocol: general notes
The module control can be equipped with various interface protocols (e.g. profibus DP). The corresponding
interface modules must be installed in the MMC for connecting to the peripherals. The data protocol is the
same for all interface protocols. All data (temperatures, fault alarms, system status indications, etc.) are
available in this protocol. Communication interfaces are prepared for bi-directional operation.

See separate description

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 75 von 94 24.01.2007


5.42. M-Graph: Single channel intraday

You can graphically display all available measuring values using this online recorder. A maximum of
60 channels are displayed. All values are updated every minute.

Selecting channels:
The channels can be selected by pressing “Back” or “Forward”. You can also enter the channel number

directly. Press , to determine the channel number (all numbers with the channel designation are
displayed).

Display range of the time axis (X):


The time axis is always 24 hours. It is possible to go back for 30 days.

Scaling the measuring ranges (Y):


The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using two
parameters. You can improve the visual resolution in the desired measuring range using these parameters.

Activating:
The channels are automatically saved in the database (time period over 30 days).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 76 von 94 24.01.2007


5.43. M-Graph: Single channel

You can graphically display all available measuring values using this online recorder. A maximum of
60 channels are displayed. All values are updated every minute.

Selecting channels:
The channels can be selected by pressing “Back” or “Forward”. You can also enter the channel number

directly. Press , to determine the channel number (all numbers with the channel designation are
displayed).

Display range of the time axis (X):


The time axis can be set to 5 display ranges (1 hour/10 hours/1 day/5 days/10 days). The active range is
highlighted in green.

Scaling the measuring ranges (Y):


The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using
two parameters. You can improve the visual resolution in the desired measuring range using these
parameters.

Activating:
The channels are automatically saved in the database (time period over 30 days).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 77 von 94 24.01.2007


5.44. M-Graph: System

You can graphically display eight import measuring values using this online recorder. All values are
updated every minute.

Selecting channels:
The channels can be faded out or in by pressing their button.

Press button to see with value is aligent to which y-axis and with which scale. Press the button
again to close this help.

Display range of the time axis (X):


The time axis can be set to 5 display ranges (1 hour/10 hours/1 day/5 days/10 days). The active range is
highlighted in green.

Scaling the measuring ranges (Y):


The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using
two parameters. You can improve the visual resolution in the desired measuring range using these
parameters.

Activating:
The channels are automatically saved in the database (time period over 30 days).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 78 von 94 24.01.2007


6. Operation & display: Service menu

The service menu can be accessed by authorized staff only. Use this menu to access all important control
parameters. This menu also provides many tools for performing diverse tests.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 79 von 94 24.01.2007


6.1. System overview

All users that are active in the system are displayed in the system overview. The following functions can also
be performed:

Warm/or cold starting the PLC


Enabling a configuration for MSP

Warm/or cold starting


Attention:
When one of the two functions is activated, the CP3485 must be restarted. This briefly shuts down the entire
system. During a warm start the data remain in the RAM. During a cold start all current data are deleted.

Procedure:
Click the “Restart” button
Both buttons turn colours. The red button is for the warm start function, and the blue button is for the
cold start function.

Select the required function by clicking the required button.

MSP
The send counter indicates whether the MSP is operating properly. During normal operation, the send
counter changes by a specific amount (13) every 2 seconds. You can also release the device configuration.
To do so, click the “Configuration” button. If the “Configuration button” is active, it flashes green.
Click the button again once the configuration is finished. After 60 minutes, the system automatically ends
configuration mode.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 80 von 94 24.01.2007


6.2. Fault alarm parameters

On this page, you can set the parameters for all fault alarms. There are two options for navigating through
the parameters:

Using the forward and back arrow keys (each moves one alarm)
You can also enter the fault alarm number directly

There are two groups of fault alarms. One group monitors a digital signal for 0 and 1. The other group
monitors an analog signal for a limit value. The type of activation for analog fault alarms, whether the fault
alarm is active when the value exceeds the limit value (max signal) or falls short of the limit value (min
signal), is set in the configuration. In the first case, the fault disappears once it falls below the limit value
minus hysteresis. In the second case, the signal disappears once it exceeds the limit value plus hysteresis. A
time delay can be specified between the time when a fault appears and a fault alarm is triggered for both
fault alarm types. Response thresholds are also activated for an analog fault alarm (limit value & hysteresis).
Response to the fault occurrence can also fail for different reasons.

Emergency stop Similar to pressing the emergency button, the module is stopped
immediately. All drives are deactivated. To restart the module, you must
acknowledge the emergency stop using the reset button on the control
cabinet.
Immediate stop The module is stopped immediately. The generator switch is opened
without delay.
Controlled stop The module is unloaded. The power is lowered by a setpoint gradient. The
module is stopped.
Alarm Only an alarm message is signalled. The module continues to run.

Additional options:

Once the fault stops, it can be automatically acknowledged. Otherwise, it remains entered with the
current fault alarms until it is manually acknowledged.
You can also entirely deactivate each individual fault alarm.
You can also configure each fault alarm so that it switches on a collective fault relay.

Once the fault alarm is configured, you must also click the “Update parameter” button. The new parameters
are then active. The button turns green.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 81 von 94 24.01.2007


6.3. Parameters

On this page, you can set the parameters for all module parameters. There are two options for navigating
through the parameters:

Using the forward and back arrow keys (each moves by one number)
You can also enter the parameter number directly

The name, unit and limit values are displayed for each parameter.

Once the parameter is configured, you must also click the “Update parameter” button. The new parameters
are then active. The button remains green for 3 seconds.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 82 von 94 24.01.2007


6.4. Analog parameters

On this page, you can set the parameters for all analog values. There are two options for navigating through
the analog values:

Using the forward and back arrow keys (each moves by one number)
You can also enter the number directly

If this page is active, all fault alarms that refer to this analog value are suppressed. This allows you
to adjust sensors without fault alarms constantly appearing. Once you exit the page, the fault alarms
are active again.

You can also simulate (force) each analog value. To do so, enter the force value and activate the
force procedure. The value is evaluated in the entire program. An additional fault alarm appears
indicating that a value is forced. This makes you aware of the force function.

Signal form:
Determines the type of measured value scale according to the following diagram:
Value: Signal form: Input min. Input max.
1 Input 0 – 20mA
2 Input 4 – 20mA
3 Input 0 – 10V
4 Input PT 100 -2000 8500
5 Input thermoelement type K -27000 13720
6 Output 4 - 20mA
7 Output 0 - 20mA
8 Output 0 - 10V
9 Input PT 1000 -2000 8500

Offset:
Use offset to compensate deviations in the measuring signal which result from different line lengths
(e.g. PT100).

Decimal point:
Number of decimal places in the measured value.

Once the analog value is configured, you must also click the “Update parameter” button. The new
parameters are then active. The button turns green.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 83 von 94 24.01.2007


Switching from PT100 / PT1000:

In order to configure a channel from PT100 to PT1000, the following procedure must be selected:

- Set standard (PT100 = 4, PT1000 =9)


- Click the "Update parameter" button
- Warm-start the CP3485 (switch off the CP3485 briefly via the system overview or 24VDC
power supply). Attention: The machine must come to a standstill!

6.5. Options parameters

Use this page to configure the entire system. All optional functions can be activated or deactivated.
Only with the corresponding access level it is possible to change an option. Grey cells could not be changed
with the actual access level. With a click in the cell of the column parameterizing you can set or reset an
option. With the button “write parameter” you send the new configuration to the PLC. The PLC is checking
the new configuration to their plausibility. If there was a change to not valid combination the PLC resets the
wrong options.

You can only select those options that are also made in the hardware.
Otherwise, the CPU can run in stop mode (e.g. if a profibus module is not present but was
activated in the options list).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 84 von 94 24.01.2007


6.6. Emergency cooler parameters

On this page, you can set the parameters for all emergency cooler parameters. There are two options for
navigating through the parameters:

Using the forward and back arrow keys (each moves by one number)
You can also enter the parameter number directly

The name, unit and limit values are displayed for each parameter.

Once the parameter is configured, you must also click the “Update parameter” button. The new parameters
are then active. The button remains green for 3 seconds.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 85 von 94 24.01.2007


6.7. Room fan parameter

On this page, you can set the parameters for all room fan parameters. There are two options for navigating
through the parameters:

Using the forward and back arrow keys (each moves by one number)
You can also enter the parameter number directly

The name, unit and limit values are displayed for each parameter.

Once the parameter is configured, you must also click the “Update parameter” button. The new parameters
are then active. The button remains green for 3 seconds.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 86 von 94 24.01.2007


6.8. Heat operation parameter

On this page, you can set the parameters for all heat operation parameters. There are two options for
navigating through the parameters:

Using the forward and back arrow keys (each moves by one number)
You can also enter the parameter number directly

The name, unit and limit values are displayed for each parameter.

Once the parameter is configured, you must also click the “Update parameter” button. The new
parameters are then active. The button remains green for 3 seconds.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 87 von 94 24.01.2007


6.9. Test Facility

Use the Startup button to start or stop the startup program.


(Key switch must be on “Release module”, “Local control” and “Automatic”.)

The 4 power levels of the startup program are displayed in the upper left side of the screen. The current
level, i.e. at which position the startup program is, is displayed on the top right side of the screen. The lower
part of the screen indicates whether the startup program has been run properly (the corresponding LED
turns green). If a stop interrupts the startup program during one of the phases, the time and levels already
expired are stored. Once the fault has been remedied, the program continues at the stored startup mode
position.

Logging
Click the “Logging” button to release the measuring data transmission to the MDE test stand. To do so, plug
a serial cable into the RS232 and connect a TTY converter between the two. Once the log is completed, you
must click the button again. Otherwise the interface remains occupied.
Attention: If an additional interface (RS232) in the project is active, this communication must be deactivated
while logging.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 88 von 94 24.01.2007


6.10. M-Graph: Single channel

See description chapter 5.43

6.11. M-Graph: Single channel intraday

See description chapter 5.42

6.12. M-Graph: System

See description chapter 5.44

6.13. M-Graph: System intrady

You can graphically display eight import measuring values using this online recorder. All values are
updated every minute.

Selecting channels:
The channels can be faded out or in by pressing their button.

Press button to see with value is aligent to which y-axis and with which scale. Press the button
again to close this help.

Display range of the time axis (X):


The time axis is always 24 hours. It is possible to go back for 30 days.

Scaling the measuring ranges (Y):


The Y-axis is automatically scaled to the maximum and minimum values. You can change the axis using
two parameters. You can improve the visual resolution in the desired measuring range using these
parameters.

Activating:
The channels are automatically saved in the database (time period over 30 days).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 89 von 94 24.01.2007


6.14. M-Graph: Heating Water

You can graphically display all important values of the heating water controller using this online recorder.
A maximum of 8 channels are displayed. The controller reads all values in one second cycles.

Switching on/off channels:


The channels can be displayed/or hidden by pressing the corresponding buttons.

Display range of the time axis (X):


The time axis can be set to 4 display ranges (1 / 5 / 10 /15 min). The active range is highlighted in green.

Scaling the measuring ranges (Y):


Two Y-axes are available: The actual values are scaled in % on the left side. The actual values are
scaled in °C on the right side. You can change both axes using two parameters. You can improve the
visual resolution in the desired measuring range using these parameters.

Activating:
Click “M-Graph on” to activate the M-Graph. Click the button again to end the function.

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 90 von 94 24.01.2007


7. Hardware descriptions

7.1. IPC

7.1.1. Possible fault causes


No power supply => measure the voltage at the plug.
Incorrect power supply polarity => check the plug
External keyboard and mouse (optional pluggable) may be incorrectly connected.
Defective memory => generally a message appears when you start the computer
PC starts but the screen is blank => touchscreen may be defective
Accessories (e.g. ISDN card) are incorrectly connected or defective
PC starts but no connection to the control can be established => check node number on the
IF681, test the Ethernet wiring, check the network card, check project settings if necessary.

7.1.2. Establish remote access (e.g. customer)

See separate description "Setting up remote access for customers V6"

7.2. Interface modules for control

See separate description

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 91 von 94 24.01.2007


7.3. CP3485
In progress!!!

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 92 von 94 24.01.2007


7.4. MSP
Adjusting or checking CAN connection to PLC:

Screw the CAN connector on CP3485 onto the left hand “CAN” interface.
Check node number on PLC.
Connect CAN lead to MSP and set the correct CAN-ID (set via MSP Display).

During transmission of operating system for PLC Baud rate must be set to 125 kbit/s. Control may
function at 500 kbit/s, but “MSP” cannot function with more than 125 kbit/s.

Set MSP parameters on display:

“Select” “Numeric” “Position”

Switch power on.


Input “34” on MSP must set to a 24V signal and input “33” to 0V.
Selecting input mode: Press “numeric” and “position” together at same time => input mode will start
and the “Test” LED flash. The system is now in parameterising mode. If you wish to exit this mode at
any time, press down “Numeric” and “Position” again simultaneously.
When in parameterising mode, pressing the “Select” key will move you through the various
parameters (forwards only).
When desired parameter has been found, setting can be adjusted by pressing “Numeric” button. For
parameters of more than one position, set the cursor to the right position by pressing the “Position”
key. Pressing the select button, confirms the parameter setting.
To exit parameterising mode, press “Numeric” and “Position” keys down again simultaneously.

Important Basic Settings:


Set “Direct parameterising” to “Off”.
Set “Generator Number” to “1”
Set “Base ID” to “0600”
Set “Parameterising ID” to “0620”
Set “Control via interface” to “On”

Parameterising via LeoPC

See separate description "LEOPC"!

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 93 von 94 24.01.2007


7.5. LAP 2440-3 Battery charging device
Output voltage is set using a potentiometer. This is located on right next to the output terminals (underneath
device).

MMC-4000-Bedienungsanleitung_V1_Englisch.doc Seite 94 von 94 24.01.2007