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PowerSync Training 4-Apr-2010

PowerSync Controller Training


April 4, 2019
Reliable power when and where you need it.
Clean and simple.

4-April-2019 Confidential. Do Not Distribute.

Hardware & Software


 Attendee Equipment
 PC – Windows 7 or later, latest Java, Ethernet & Internet connectivity

 Software Tools to be Provided


 Batch File for Remote HMI Access
 Presentation Material (pdf)
 Latest Documentation
 Configuration Form (spreadsheet)
 Example Visio Network Diagram

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PowerSync Training 4-Apr-2010

Training Course Outline


Day Morning Afternoon
Thurs PowerSync Overview HMI Overview
What’s In the Box Log In / Control Priority
Communications / IP Scheme Dispatch Logic & Load Following
Local / Remote & Start Enable / Stop
Friday TNS & Service Inputs Seamless Transfer
Modbus TCP Communications Exam
File Structures and Retrieval
Configuration Form / Customization

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PowerSync Controller - Overview


 PowerSync Controller – Objectives
 PowerSync Family Overview
 PowerSync Features & Benefits
 Which PowerSync Controller to Use?
 Phoenix Contact
 Controller Shipment and Commissioning
 Documentation & Training
 New C1000 Catalog Structure
 Price List
 Q&A
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PowerSync Controller - Objectives


 Increase Reliability/Availability
 No Single Point of Communications Failure for Control
 Fault Tolerant System Design
 Pretested Function Modules
 Integrate with External Control/Monitoring Equipment
 Industry Standard Communications Protocols (e.g. Modbus TCP/IP)
 Reduce Requirement for Capstone Custom Programming
 Increase Base Functionality (e.g. easy configuration & operation)
 Modular Industry Standard Components (PLC based)
 Distributor Training for PLC & HMI Customization
 Enhance Troubleshooting/Commissioning Capability
 Transient Operation and Event Information
 Improved Field Service Connectivity (e.g. WiFi/Internet)

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PowerSync Controller Family


 PowerSync MultiMaster
 Controller for Multiple C200/C1000
Systems

 Controllers for C1000 Series


 PowerSync Master
 Full functionality for single system installations
 PowerSync Enhanced
 Full functionality for multiple system
installations when used with MultiMaster
 PowerSync Lite
 Limited functionality - no controller installed
 Acts as individual C200 modules
PowerSync MultiMaster PowerSync Master/Enhanced
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PowerSync
Controller
Family

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PowerSync Masters Block Diagram


PowerSync MultiMaster or PowerSync Master Controller

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PowerSync Masters MCB


• Purpose
 MCB acts as the Multipac Controller the same way as the CLC, APS and
Unit#1 Microturbine in the native Multipac system.
 MCB is in charge of Multipac Communications and Control

• Changes/New Functionalities
 Improved communication speed
• Changed the MultiPac structure definitions to reduce the MultiPac data
structure sizes
• Changed the MultiPac update command to asynchronous communication
 Updated MultiPack state machine for ease of PLC interface
• Added PLCDAT, PLCCOM, SYSINF and PLCSTR for PLC control
 Updated the time synchronization from one month to one minute
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PowerSync Master and MultiMaster Attributes


• Both are Full-Function MultiPac Masters using MCB
• Common PLC Hardware, Ethernet Switches, I/O Modules
• Consistent Operator Interface & Remote HMI Sessions
• Same External Equipment Interfaces
– Consistent Default Modbus TCP Tables
– Hardwired Stop/Start, Analog Inputs, RS-485 for Power Meter…
• PowerSync Master Controller Uses Same SW with or w/o PSMM
– Jumper tells PLC how to perform
– Bypasses MCB when connected to a MultiMaster (aka “Flat-Pack”)

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PowerSync MultiMaster/Master
• Common Wiring Locations/Designations
• Customer Wiring on TB1
• Pre-Defined Input and Output Functions
• Space for Additional Accessories:
 mGuard & WiFi Modules
 Remote I/O Module for Seamless Transfer
 Additional PLC I/O Modules for MultiMaster
• Example Digital Inputs - Next Slides

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PowerSync
MultiMaster
Digital Inputs

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PowerSync
Master
Digital Inputs

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PowerSync
Controller
Family

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C1000S PowerSync Controllers


 PowerSync Master
 Full-Function MultiPac Master using MCB
 I/O for External Connection Options
 Includes Local Pushbuttons & Touch Panel HMI
 PowerSync Enhanced
 Requires MultiPac Master (no MCB)
 Reduced I/O
 Includes Local Pushbuttons & Touch Panel HMI
 PowerSync Lite
 Primarily a Connection Box for Communications
 Treats the C1000 like individual C200’s

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C1000 PowerSync Controller Feature Master Enhanced Lite


Independent MultiPac Control (MultiPac Master) ●
Works with PowerSync MultiMaster for MultiPac Control ● ● ●
Self-Healing Ring Communications for MultiPac Control ● ● ●
Ethernet Service Port ● ● ●
Prewired for Seamless Transfer ● ● ●
Ready for Integrated HRM Inputs * ● ● ●
Available with LPG/Butane Fuel Control ● ●
Available with HH Controls ● ●
End Bay & Fuel Temp RTD’s and CB Position Indication ● ●
Touch Screen HMI ● ●
Start/Stop Pushbuttons & Local/Remote Key Switch ● ●
Integrated UPS (30 minutes) ● ●
* PSL requires custom configuration for integrated HRM
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PowerSync MultiPac Connection Options

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Which PowerSync Controller to Use

C1000 PowerSync Controller Expected Application


PowerSync Master • Single Unit sites without MultiMaster
PowerSync Enhanced • Multi Unit sites with MultiMaster
PowerSync Lite • One or Two Unit Sites with MultiMaster, or
• GC-Only Sites using CRMS for individual MT setup
Note: No LPG/Butane or HH Package Options

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Which PowerSync Controller to Use


PSMM Use with Signature Series PowerSync Line
C1000S PowerSync Single Unit Site Number of C1000S Packages
Controller Options 1 2 3 4 5 6
DM N R R R R R
PSM
GC N N N N N N
DM R R R R R R
PSE
GC R R R R R R
DM R R Multi Unit Site
PSL RX == PSMM
PSMM Required, N = PSMM Recommended, but not required,
GC X X
Recommended, but not required if using CRMS to Control Each Individual Bay

R = PSMM Required Special Grid Connect Only Case


N = PSMM Recommended, but not required
X = PSMM Recommended, but not required if using CRMS to Control Each Individual Bay
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Phoenix Contact

Phoenix Contact develops and manufactures industrial electrical and electronic technology
products that power, protect, connect, and automate systems and equipment for a wide
range of industries. Phoenix Contact GmbH & Co. KG, Blomberg, Germany operates 50
international subsidiaries, including Phoenix Contact USA in Middletown, PA.
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Phoenix Contact Employees worldwide 14,330

. . Sales in million 1.92 Billion €


. . 10% Average Growth Rate

Sales

Germany International
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Phoenix Contact AXC 3050 PLC


• General Specs:
 Intel® Atom™ 1.3 GHz Processor
 Programing Software: PC WORX
 3x 10/100 MBit/s Ethernet Ports
 Extended Operating Temperatures 25ºC
... +60ºC
 2 GB SD card for Program and
Configuration Memory
 Up to 63 AXIOLINE I/O modules (either
direct or using remote I/O)

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Shipment of PSMM Controllers


Type of Controller Sale Controller Ships to Test Confirmation
Standard MultiMaster Drop Ship to Site
On Site Commissioning
Controller (or Capstone if FAT)
Applications confirms SW using
MultiMaster Controller with Drop Ship to Site bench test unit
Applications Customization (or Capstone if FAT) +
On Site Commissioning
after Capstone Authorized Systems Integrator Training:
Distributor confirms SW using
MultiMaster Controller with their controller
Drop Ship to Distributor
Distributor Customization +
On Site Commissioning
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Commissioning of PSMM Controllers


Type of Controller Sale Customization Commissioning Support
1. Distributor ASP
Standard MultiMaster None
2. Capstone Service
Controller (Site Configuration Only)
3. Capstone Engineering
1. Distributor ASP
MultiMaster Controller with Power or Flow Meter 2. Capstone Service
Applications Customization Graphics (e.g. one-line) 3. Capstone Applications
BOP (e.g. fuel skid) 4. Capstone Engineering
Custom Modbus Tables 1. Distributor ASP
MultiMaster Controller with Customer Control Logic 2. Capstone Service
Distributor Customization
3. Capstone Engineering

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PowerSync Controller Feature Customer Benefit


• Consistent HMI with Easy Navigation • Reduce Operator Training Costs
• Remote HMI Access with Control Priority • Increase Uptime
• Secure System Operation
• Self-Healing Ethernet Ring for Control • Increase Uptime
• Reduce Service Costs
• Standard Dispatch with Auto Select Logic • Reduce NRE
• Reduce Operating Costs
• Next Scheduled Service Indicator & • Control Service Costs
Service Log • Increase System Uptime
• Event & Configuration File Log • Reduce Troubleshooting Time
• Reduce Service Costs
• Trend and Data Logs • Optimize System Operation
• Standard Modbus TCP/IP Connection • Reduce NRE for BMS Connection
• Customizable HMI & PLC Logic • Accommodate Site-Specific Requirements
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PowerSync Controller Documentation


 PowerSync Configuration Form
 Currently in Use (420010)
 For All PowerSync Controllers (with or without custom programming)
 Automatically Generates Controller “Config File” to Expedite Setup
 User Manuals
 PowerSync MultiMaster User Manual (400037)
 PSM/PSE/PSL in New C1000S User Manual (400036)
 Product Specifications
 PowerSync MultiMaster Product Spec (460079)
 C1000S Series 3, 4, 5 Bay (460089)
 Technical References
 PowerSync MultiMaster Controller Tech Ref (410113)
 C1000S Signature Series with PSM/PSE/PSL Controllers (410112)

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PowerSync Controller Documentation (cont’d)


 Wiring Diagrams / Schematics (ships with each controller)
 PSMM Schematic & Wiring Diagram (534367)
 PSM Schematic & Wiring Diagram (534366)
 PSE Schematic & Wiring Diagram (534967)
 PSL Schematic & Wiring Diagram (534368)
 Price Lists / Illustrated Catalog
 US Price List (310016)
 International Price List (310057)
 Illustrated Catalog (310047)
 Installation / Applications Guides
 C1000S Signature Series with PSM/PSE/PSL Controllers (480058)
 PowerSync MultiMaster Controller (480059)
 Application Guides for Auto Select Logic & Seamless Transfer Functionality in work

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PowerSync Controller Training


 Detailed Distributor Sales & Applications Training
 2 Day Hands-On Session at Capstone (this course)
 Focus on Features/Benefits, Configuration Form, and Secure Remote Connectivity

 ASP Training
 Initial Customer Service Training at Capstone October 29, 2018
 Target Distributors Who Have or Expect to Order PowerSync systems

 Authorized Systems Integrator Training


 Provides Qualified Distributors the Capability to Customize the MultiMaster
 Initial ASI Training at Capstone October 22-26, 2018

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New “Baseline” Configuration


 The new standard (a.k.a. baseline) configuration now includes the
PowerSync Lite (PSL) controller
 The C1000 Controller is no longer the standard controller but still
available
 The other PowerSync controllers can now be ordered

1000 S - H G 4 - B U 0 0 - A 0 0 0

Option 3: Controller
0 = PowerSync Lite Controller
A = C1000 Controller
R = PowerSync Enhanced Controller
S = PowerSync Master Controller

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PowerSync Pricelist Items


 PowerSync MultiMaster Controller (534367-100)
 One Catalog/Part Number for C200/C1000 (GC or DM)
 Standard HMI & PLC Software – user configurable
 Applications Customization – NRE Charge based on Configuration Form
 PowerSync Master/Enhanced/Lite
 Specify which one in every C1000 Signature Series system order
 Master/Enhanced models required for LPG/Butane, and High Humidity Cat Numbers
 Integrated HRM will be field installed
 Field-addable Phoenix Contact Components
 mGuard Secure VPN Routers & WiFi Module
 6 and 8 port Managed Ethernet Switches

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Additional Pricelist Items


 Seamless Transfer Accessories
 SEL-700GT Protective Relay (can also act as power meter)
 SEL-2505 Remote I/O Modules
 PowerSync Controllers Pre-Configured to Read these Devices

 Field System Upgrades – Case by Case


 Existing C200/C1000 to New PowerSync MultiMaster
 PowerSync Enhanced / Lite to Existing CLC
 Existing CLC / C1000 Controllers System to Complete PowerSync Controller System

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Questions?

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Hardware
Review

PowerSync MultiMaster PowerSync Master PowerSync Enhanced


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Documentation Wake Circuit

• Schematic & Wiring Diagram (in pocket) Example

• Circuit Schematics (in Tech Ref)

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Hands On & Questions?

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PowerSync Controller - Communications


 Three Capstone Networks
 Self-Healing Ring for MultiPac Control
 Fault Tolerant MCB Operation
 IP Scheme
 Example Network Connections
 mGuard Secure VPN Router
 Time Synchronization
 Network Trap Manager
 Digital Communications Media

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PowerSync Communications Purpose


Controller Type
ESW1 RS232 User & Connect to an individual microturbine with a PC or PLC
Monitoring & Maintenance Ports to retrieve real time and fault history data, adjust
Service settings, and download software. PowerSync
controllers connect to the Maintenance port.

ESW2 COAX Ethernet Connects microturbines to a Master Controller to


MultiPac Control Multipac Master manage a “Multipac”
RS485 Inverter Broadcasts time-critical information to synchronize
Synchronization multiple microturbine inverter outputs. Required for
Stand Alone.

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PowerSync MultiMaster
Major Components

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Optional
Customer

PowerSync Master
24 VDC

EPDB PSM Controller

Major Components
400/480 VAC Power 24 VDC
50/60 Hz Supply
*
* UPS Touch Panel HMI
Terminator UPS
10Base-2 Battery X5

* MCB RS-232
UCB UPS 24
10B2 to VDC*
10BT RS-232
Converter
Reserved for *
Optional HRM**
Serial to

10/100Base-T
To PSMM Ethernet
ESW2 Copper
MultiPac Control Converter
Option
Bay A SCM Expanded View *

Terminator X3 X6
10B2 to 10/100Base-T
10Base-2 10/100Base-T X1 X5 *
10BT 10/100Base-T 10/100Base-T X2 X3
Converter In X2 X4

Out X7 X1
AXC 3050 I/O
UCB RS-232 Ethernet Ring PLC Modules
Serial to X8
Switch
Ethernet
RS-232 Fiber Option
Converter To PSMM

10/100Base-T

Ring In
10/100Base-T
Bay B SCM S/E Converter *
Ring Out X3 X1 Copper
X4 X2 Option To PSMM
Ring In X10
10/100Base-T X5
Bay C SCM S/E Converter
X6 X11
WiFi/M Guard
Ring Out Option
X7 X12
X8 X13 Fiber
Ring In
10/100Base-T X9 X14 Option
Bay D SCM S/E Converter
To PSMM
Ring Out ESW1
Monitoring/
Ring In Service
10/100Base-T
Bay E SCM S/E Converter
Surge
Ring Out
Suppresors

* 24 VDC from UPS distributed to controller components Service Customer


** HRM may be connected to 2-port Serial to Ethernet Converter Port BMS

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PowerSync Enhanced
Optional
Customer
24 VDC

Power Connection Bay PSE Controller

Major Components 400/480 VAC


50/60 Hz
Power
Supply
24 VDC

UPS
*
Touch Panel HMI
UPS UPS 24
Battery VDC* X5

Reserved for
Optional HRM**

Bay A SCM Expanded View *


X2

Terminator X1
10B2 to AXC 3050 I/O
10Base-2 10/100Base-T
10BT PLC Modules
Converter In
Out

UCB RS-232
Serial to Ethernet Ring
Ethernet Switch
RS-232
Converter
10/100Base-T *
X3 X1 Copper
To PSMM
X4 X2 Option
Ring In X5 X10
10/100Base-T WiFi/M Guard
Bay B SCM S/E Converter X6 X11
Option
Ring Out X7 X12
X8 X13 Fiber
Ring In Option
10/100Base-T X9 X14
Bay C SCM S/E Converter To PSMM
Ring Out ESW1
Monitoring/Service
Ring In
10/100Base-T
Bay D SCM S/E Converter
Ring Out

Ring In
10/100Base-T
Bay E SCM S/E Converter
Surge
Ring Out
Supressors

* 24 VDC from UPS distributed to controller components Service To PSMM


** HRM may be connected to 2-port Serial to Ethernet Converter Port ESW2 Ring

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PowerSync Lite
Optional
Customer
24 VDC

Power Connection Bay PSL Controller

Major Components 400/480 VAC


50/60 Hz
Power
Supply
24 VDC
24 VDC*

Reserved for
Optional HRM**

Bay A SCM Expanded View

Terminator 10/100Base-T
10B2 to
10Base-2 10/100Base-T 10/100Base-T
10BT
Converter In
Out

UCB RS-232
Serial to Ethernet Ring
Ethernet Switch
RS-232
Converter

10/100Base-T

Ring In
10/100Base-T
Bay B SCM S/E Converter
Ring Out

Notes: Ring In
10/100Base-T
*
X2 X1
Bay C SCM S/E Converter

 “Lite” can connect to “MultiMaster” or be Ring Out


X3
X4

used as a low cost connection to other


X5 X7
Ring In
10/100Base-T X6 X8
Bay D SCM S/E Converter

equipment in GC-Only Applications Ring Out Surge


ESW1 Supressors
Monitoring
Ring In

 “Lite” uses smaller box size with same 10/100Base-T and Service
Bay E SCM S/E Converter
Ring Out

connections to each bay as PSM & PSE


Service Out In
Port Ethernet
Ring
* 24 VDC from UPS distributed to controller components
To PSMM Controller
** HRM may be connected to 2-port Serial to Ethernet Converter

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PowerSync
C1000 Bay
Connections

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PowerSync C200 Connections


C200 Upgrade Kit Components

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PowerSync Master Ethernet Ring


• PLC Monitors Ethernet Switches for Port Comm Loss
• Staggered Ring Port Connections Identify Location

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Redundant Ring for MultiPac Control


 Used for MultiPac Control (aka “COAX” Ethernet)
 Two Paths for Communications
 Normally Operates Like a Daisy Chain

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Redundant Ring for MultiPac Control


 Example Break between B & C
 Ring Switches Automatically Establish Alternate Path (<30ms)
 Network Initiates Alarm to Identify Fault for Corrective Action

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Fault Tolerant MCB Operation


 MCB Monitors PLC Comm

 MCB Enters “Limp Along” Mode if Comm Loss


More than 60 Seconds:
 Starts All Available Turbines
 If in Stand Alone – Maintains Last Commanded Voltage / Frequency
 If in Grid Connect – Brings All Units to Idle (Override Power Demand = 0)
 Initiates Alarm Relay Output on MCB’s JUCB (CRMS “PLC Comm Loss”)

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Control Network
Coupled Ring
Fiber Example

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Control Network
Coupled Ring
CAT6 Example

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Control Network
Direct to C1000 Bays
CAT6 Example

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Service Network
Star to Star
CAT6 Example

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Network IP Scheme
Example PowerSync Controller Digital Communications Networks
PSMM with one or more PSMM with up to 10 C200's
Single C1000's with PSM
C1000's with PSM/PSE or up to 2 C1000's with PSL
Controller
Controllers Controllers
Addressable Control Service Control Service Control Service
Devices 192.168.1.xx 172.17.10.xx 192.168.1.xx 172.17.10.xx 192.168.1.xx 172.17.10.xx
HRM's MT # MT # MT #
2, 3… 2, 3… 2, 3…
C1000 MCB S/E 101
MT RING ESW MT # + 100 MT # + 100 MT # + 100
102, 103.. 102, 103.. 102, 103..
MT S/E MT # + 100 MT # + 100 MT # + 100
102, 103.. 102, 103.. 102, 103..
C1000 ESW1 141 14x 141*
(x = C1000 #) 142*
C1000 ESW1 X10 15x
Ext. Device (x = C1000 #)
C1000 ESW1 X11 16x
Ext. Device (x = C1000 #)
C1000 ESW2 171 17x
(x = C1000 #)
C1000 HMI 181 18x
(x = C1000 #)
C1000 PLC 191 191 19x 19x
(x = C1000 #) (x = C1000 #)
PSMM PLC 200 200 200 200

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Network IP Scheme
(example map)

Service Control

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Two C1000’s
Example 1
(Fiber)

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Two C1000’s
Example 2
(CAT6)

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Two C1000’s
Example 3
(CAT6)

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Three C1000’s
Example (Fiber)

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C1000 + C200
Example
(CAT6)

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Remote Access

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mGuard Accessories (4000 Series)


• Secure VPN Routers
 Isolate PowerSync Network
• Industrial Grade
• Phoenix Cloud Service Included
• Two Digital Alarm Inputs
 Send email messages for Action
Alarm and Maintenance Indicator
Outputs
Standard 4G Cellular
WAN to LAN WAN to 4 LAN’s
(2 US ATT/Verizon, 1 EU)

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WiFi Module Accessory


• Provides Local Wireless Connectivity
• Install on the WAN side of mGuard
• Example C1000 Engineering Unit

WiFi Module with Antenna

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Time Synchronization
 Controllers Synchronize Time Every Minute
 Expect less than 1 second time difference between devices
 Setup Options include
 using HMI’s internal clock (operator sets initial time & updates)
 BMS writes time into Modbus registers
 Internet Time, when PSMM Industrial PC has a WAN connection
(mGuard can synchronize with Internet Network Time Protocol “NTP”
server, and IPC sets mGuard as its NTP reference)

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Ethernet Switch Trap Manager


 Ethernet Switches need to point to Trap Manager for network status
 Good for both Control and Service Networks
 Trap Manager IP’s:
PSMM PSM alone PSM/PSE/PSL*
First its PLC its PLC PSMM’s PLC
Second its IPC Service - its HMI PSMM’s IPC
Control – Use .210
* Connected to PSMM

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Digital Communications Media


Communication Media Termination Max Run Comments
Multimode Optical Fiber ST Connection 4km (13,000 ft) • High electrical noise
(50 or 62.5μm) between immunity
Ethernet • Eliminates galvanic
Switches interconnections
CAT6 Cable RJ45 100m (330 ft) • Include surge
between suppressors for
Ethernet MultiPac control
Switches connections
RS-485 Shielded Twisted Terminal Block 300m (1000 ft) • Account for 60 ft
Pair Total run from internal run for
(min 18 awg wire) end to end each C1000
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Hands On & Questions?

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Consistent HMI
PowerSync MultiMaster PowerSync Master/Enhanced
Capstone Branding

Consistent
Data Format

Easy Navigation
12 Monitoring Screens 7 Monitoring Screens
8 Setup & Control Screens
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PowerSync Training 4-Apr-2010

PowerSync Master/Enhanced Panel


Key Allows Local
LED Indicates Operator to Stop
Bus Voltage is C1000S System
Present

LED Confirms Confirms All LED


Controller is Indicators are
Ready Working

LED Indicates that C1000S LED Indicates that C1000S


System is ON System is OFF
Start Enable Pushbutton to Stop Pushbutton Control
Allow Start in Key Local in Key Local

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PSM/PSE HMI

Main Monitoring Screen

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PowerSync Training 4-Apr-2010

PSMM HMI
(also PSM
Remote HMI Same as
Session) PowerSync
Master
Local Main
Screen

Main Data Screen


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PSMM HMI
C1000 Level
Data &
Sub-screen
Selection

C200 & Bay Level


Data & Sub-screen
Selection

Main Microturbines Screen


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PowerSync Training 4-Apr-2010

PSMM HMI
(also PSM
Remote HMI
C1000 Level
Session) Data

Bay Level Data

Main Microturbines Detail Screen


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Event Log Screen

Key User Activity

Communication
Events

C1000 Package
Events

Traditional MT
Fault Events

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36
PowerSync Training 4-Apr-2010

PSM vs PSMM HMI Screens


• Consistent Data Presentation & Navigation
• Always Know Which Screen is Being Viewed
• Both Include 2 Remote HMI Session Screens
• PowerSync Master Remote HMI Screens:
 Same as MultiMaster Screens (with a few exceptions)
 Master Setup only done on Remote HMI Session Screens
 Master Remote HMI Session Screens not active when connected to
a MultiMaster (go to the MultiMaster remote session for all
monitoring & control)

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Hands On & Questions?

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37
PowerSync Training 4-Apr-2010

Authorized
User Setup
• Admin Sets Up New Users
• Admin Can Remove User
• Users Require Log In
Password
• Passwords can be changed
• Setup Changes require
“Control Priority”

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Multi-User Log In with Control Priority


Control Bar Appears on all Setup and Control screens

• Up to 3 Independent Sessions:
1 Local, 2 Remote
• Red Border indicates Authorized User
Logged In
• Green Background indicates User with
Control Priority
• “Guest” or “Local” indicates someone
viewing, but not Logged In

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PowerSync Training 4-Apr-2010

Control Bar Examples

• Local Activity on the PowerSync MultiMaster Controller


• No Remote HMI Session Connections

• Mr. ASP1 Logged In with Control Priority on Remote HMI Session


• One view-only Local and one view-only Remote HMI Session Guest

• Admin Logged In on Local MultiMaster Display with Control Priority


• Mr. ASP1 Logged In on Remote HMI Session
• One view-only Guest on third Remote HMI Session
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Control
Screen
Example Same as
Main Screen

Admin Has Only User with Control Priority can


Control Priority Start/Stop or Initiate Reconnect Commands

Control Screen

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PowerSync Training 4-Apr-2010

PSM
Microturbine Setup
• Turbine Designation
• Type of System
• IP Addresses
• Catalog & Serial Numbers

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PSMM
Microturbine Setup
• Matrix 6 Rows x 5 Columns
• Top 2 Rows either C1000’s or
C200’s
• Bottom 4 Rows only C1000’s
• Selecting Left Boxes brings up
Setup Screen similar to PSM

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40
PowerSync Training 4-Apr-2010

Grid Connect Setup Screen


MultiPac Level
• Start/Stop
• Power
Demand
• Power Factor

Turbine Level
• Control Logic
• Auto Select
Settings

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Stand Alone Setup Screen


MultiPac Level
• Start/Stop
• Start Setting
• Run Settings

Turbine Level
• Control Logic
• Auto Select
Settings

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41
PowerSync Training 4-Apr-2010

PSM
HRM Setup
• IP Addresses
• Mode & Setpoint Fixed or
Modbus TCP Control
• Additional HRM Setup Info

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Demonstration & Questions?

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42
PowerSync Training 4-Apr-2010

Dispatch Elements
 The process of turning microturbines on and off and setting their
output power
 Need to Answer Four Questions:
1. When to Start/Stop (what Time, or who has control)
2. What Amount of Power is Required
3. How Many Microturbines Are Needed for that Power
4. Which Ones Should be Selected

Acronym: WAMO
When, What Amount, How Many, Which Ones

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Simple Dispatch Example


 SS Capstone is approaching a storm, and the Captain needs
the full crew to control the ship.
 The Four Dispatch Questions:
1. When to Start/Stop (or who has control)
The Captain issues an immediate command
2. What Amount is Required
“all hands on deck”
3. How Many Are Needed for that Request
The entire crew
4. Which Ones Should be Selected
All crew members that are able (e.g. not sick or injured)

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PowerSync Training 4-Apr-2010

Another Dispatch Example


 An emergency call comes in that there is a fire in a small
commercial building.
 The Four Dispatch Questions:
1. When to Start/Stop (or who has control)
An emergency responder determines the nearest fire station and sends an immediate
message:
2. What Amount is Required
“One-alarm fire at address xxx”
3. How Many Are Needed for that Request
A one-alarm fire requires one pumper and one rescue vehicle
4. Which Ones Should be Selected
The first pumper and rescue vehicle in line that are available

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Another Dispatch Example


 A horse race is scheduled for 1pm
 The Four Dispatch Questions:
1. When to Start/Stop (or who has control)
The race starts at 1pm (this is like “Time of Use”)
2. What Amount is Required
A full lineup of race horses
3. How Many Are Needed for that Request
Six – that’s how many starting gates there are
4. Which Ones Should be Selected
The six fastest horses from the previous day’s qualifications

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PowerSync Training 4-Apr-2010

PowerSync Dispatch Elements

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Dispatch
Requires
“Availability”

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PowerSync Training 4-Apr-2010

Turbine Dispatch Control Options

OFF

Modbus TCP Write Registers Can Control Turbine Dispatch Two Ways:
1. Direct Turbine Control using:
 Start/Start bits for Available Turbines Set for “Auto” Control
2. Indirect Turbine Control using:
 Power Demand, Spinning Reserve, and Min Run Capacity
 Auto Select Settings (Stop Delay, Delta TNS, and OFF Timer)

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Objectives for “Good” Dispatch Logic


A Good Dispatch Control Logic will:
• Consider both Running Time and Start Cycles
• Rationalize Expected Service Among Units
• Remain Stable Under Varying Load Conditions
• Allow Maximum Operating System Efficiency
• Provide Simple Customer Adjustments
• Be Easy to Understand and Implement

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46
PowerSync Training 4-Apr-2010

Capstone’s Auto Select Logic


(aka Max Efficiency with Runtime Balance)

Customer Drivers:
• Increased Electrical Efficiency
• Improved Emissions
• Increased Equipment Life
• Predictable Service Intervals

Maximize Return on Investment


(minimize variable operating costs)
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Auto Select Logic Adjustments

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PowerSync Training 4-Apr-2010

Auto Select Logic Tasks


1. Operate the minimum number of microturbines to achieve the
requested power capacity.
• This helps to assure the best overall electrical efficiency for the MultiPac and
controls service costs related to turbine operating hours.
2. Minimize the number of unnecessary start / stop cycles on each
turbine.
• This helps reduce excess fuel consumption during startups and controls
service impacts due to number of start/stop cycles.

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Auto Select Logic Tasks


3. Select the turbines to start and stop such that their expected next
scheduled service dates are within a user-defined window.
• This allows service technicians to cost effectively plan work and minimizes
customer downtime.
4. Avoid leaving a turbine off for extended time periods.
• This can be important when turbines are connected to a common exhaust
header and helps keep batteries properly charged in stand alone
applications.

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48
PowerSync Training 4-Apr-2010

Variable Operating Cost Drivers


• Fuel
 Cost of Fuel (e.g. natural gas at $6.00/MMBTU)
 Microturbine Efficiency (e.g. Load, Ambient Temperature,..)
 Parasitic Loads (e.g. fuel gas booster)
 Net Fuel Consumption during Start/Stop (secondary effect)
• Maintenance
 Operating Hours
 Engine Starts/Stops (combustor starts)
 Microturbine Model (e.g. GC vs DM)
 Load Variation (e.g. battery life due to cyclic loads)

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Example
Operating
Cost vs Load
Steady State Operation
57%
Increase

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PowerSync Training 4-Apr-2010

Example How Many Microturbines


Load
Profile

Requested Capacity = Actual Load + Spinning Reserve


Number of Microturbines = Requested Capacity / MT Unit Capacity
Stop Delay Reduces Unnecessary Start/Stop Cycles
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Example
Sensitivity
Analysis

Fuel and Maintenance Costs Not Dependent on Stop Delay Times

Utilize Reasonable Stop Delay Times to Improve System Reliability


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PowerSync Training 4-Apr-2010

Grid Connect Setup Screen


MultiPac Level
• Start/Stop
• Power
Demand
• Power Factor

Turbine Level
• Control Logic
• Auto Select
Settings

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Stand Alone Setup Screen


MultiPac Level
• Start/Stop
• Start Setting
• Run Settings

Turbine Level
• Control Logic
• Auto Select
Settings

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PowerSync Training 4-Apr-2010

Load Following Smoothing Filter

103
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Demonstration & Questions?

104
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52
PowerSync Training 4-Apr-2010

Local vs Remote & Start Enable/Stop


The W in WAMO

Acronym: WAMO
When, What Amount, How Many, Which Ones

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Local vs Remote & Stop/Start Enable


• Basic Design Philosophy
 System Stop is Higher Priority than Start
 Hard Wired Inputs Direct to MT Bays have Priority (i.e. EStop/Fault)
 Operator at a C1000S has Higher Priority than Remote
 Starting a System requires Multiple Conditions to be TRUE
 System Level Starts and Stops are Recorded in the Event Log
• PowerSync Controllers Provide Multiple Setup Options
 Tradeoff of Flexibility vs Complexity
• PSMM and PSM/PSE are Slightly Different

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PowerSync Training 4-Apr-2010

PSMM vs PSM
Conceptual System Start/Stop Diagrams

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PSMM MultiPac Control


• Key Switch Disables (STOP) or
Enables (OK to RUN) System
• HMI Can Always Stop Override
(with Control Priority)
• Starting the MultiPac Requires
both:
 Key Switch in “OK to RUN”
 Selected START/STOP Control
Setup Input Active

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PowerSync Training 4-Apr-2010

PSM MultiPac Control


• Key Local Stop
 STOP Pushbutton can always STOP
the MultiPac
• Key Remote Stop
 Selected Setup Option Input can
always STOP the MultiPac
 Remote HMI Session can always
STOP the MultiPac (control priority)
• Starting the MultiPac Requires:
 Key Remote (OK to RUN)
 Selected Setup Option Start/Stop
Input to START Active

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PowerSync Master/Enhanced Panel


Key Allows Local
Operator to Stop
C1000S System

LED Indicates that C1000S LED Indicates that C1000S


System is ON System is OFF
Start Enable Pushbutton to Stop Pushbutton Control
Allow Start for Local PB Setup in Key Local

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PowerSync Training 4-Apr-2010

PSM Local vs Remote


PSM Controller Pushbutton
Key Switch Position
MultiPac Start/Stop Control Setting STOP
Local PB / Remote HMI Stop
Local
Modbus, Latched Input, or Pulsed Input Stop
Local PB / Remote HMI Stop
Remote
Modbus, Latched Input, or Pulsed Input No Control

PSM Controller Pushbutton


Key Switch Position
MultiPac Start/Stop Control Setting START ENABLE
Local PB / Remote HMI
Local No Control
Modbus, Latched Input, or Pulsed Input
Local PB / Remote HMI Start
Remote
Modbus, Latched Input, or Pulsed Input No Control

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PSM / PSE
Conceptual System
Start/Stop Diagram
when connected to a
PSMM

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PowerSync Training 4-Apr-2010

PSM / PSE Local vs Remote with PSMM


Pushbutton Pushbutton
Key Switch
STOP START ENABLE
 Running turbines
immediately stop.
 All bays are prevented  No Change
LOCAL from running under PSMM  Transition message “Under
control. PSMM Control”.
 PSMM blocked from
issuing starts.
 No change.  No change.
REMOTE  Transition message “Under  Transition message “Under
PSMM Control”. PSMM Control”.

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Exercise & Questions?

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PowerSync Training 4-Apr-2010

Service Log

Any Authorized
User that is
Logged In can
enter new
Service Data

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Service Log
System
Recalculates
“Next Service Due”
every 24 hours

Calculation uses
“Time to Next
Service” in hours
divided by
Rolling Average
Operating Hours
per Day to
Identify Unit with
Lowest Calendar
Days to Next
Service
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PowerSync Training 4-Apr-2010

Service Indications on HMI Screens

Next Scheduled
Service Due Info

Condition
Monitoring Alarm
(engine filter P,
electronics Temp)
Main Data Screen
117
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Demonstration & Questions?

118
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PowerSync Training 4-Apr-2010

BMS Connection at
PLC X3 (Modbus TCP)

119
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Modbus TCP
Register Map
(PSMM)

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PowerSync Training 4-Apr-2010

Example Modbus TCP Master Read

When “Modbus TCP” is selected as the Dispatch Control Logic,


the BMS system can start/stop any Available turbine that has its
Control set to “Auto”. The Stop Delay setting will apply to any
turbine the BMS commands to stop.

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Example Modbus TCP Master Write

When “Modbus TCP” is selected as the Dispatch Control Logic,


the BMS system can start/stop any Available turbine that has its
Control set to “Auto”. The Stop Delay setting will apply to any
turbine the BMS commands to stop.

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Exercise & Questions?

123
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Log and Data Files (MultiMaster)


Type Frequency Max File Size Comments On HMI?
Event Log Event Driven 10,000 lines Time Stamped with Turbine & User YES
ID (1000 lines)
Service Log Service Entry 10,000 lines Incident Report # with User ID YES
Driven (+ 40 character text for unscheduled) (1000 lines)

Configuration Log Change Driven 1,000 lines Time Stamped with User ID and Current Setup
Configuration Details
Trend Chart Data Every 30 1 year Five Key Parameters YES
Seconds (1,000,000 lines) (Six when Seamless Transfer
enabled)
MultiPac Data 1 to 30 min 10 MB User Configurable Logging Rate Current Data

Turbine Data 30 to 60 min 10 MB User Configurable Logging Rate Current Data

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PowerSync Training 4-Apr-2010

Configuration File / Log MIN_RUN_CAP=100


MIN_START_CAP=100
POWER_FACTOR=1.0
SA_VOLTAGE=480
 Example Config File (provides SA_FREQUENCY=60.0
SA_SPIN_RESERVE=100
all inputs necessary to set up a GC_POWER_DEMAND=400
system to run) ASL_MAX_DELTA_HRS=500
ASL_STOP_TIME_MIN=30
ASL_OFF_TIMER_WEEKS=1
 Configuration Log contains MCB_IP=172.17.11.20
time-stamped list of which SNTP_IP=172.17.11.60
Authorized User changed
C1000_1_TYPE=1
configurations on the HMI C1000_1_IP=172.17.11.93
along with the associated new C1000_1_SERIAL=12341
C1000_1_DESIGNATION=C1000#1
configuration file C1000_1_CATALOG=C1000CAT#1
C1000_1_C200_NUM=0

C1000_2_TYPE=6
C1000_2_IP=172.17.11.53
C1000_2_SERIAL=12342
C1000_2_DESIGNATION=C1000#2
C1000_2_CATALOG = C1000CAT#2
C1000_2_C200_NUM=3

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File Structure & Retrieval


• Files Downloadable to Spreadsheets (Excel)
• Data is Stored on the HMI
 PSMM Industrial PC includes 80GB solid state drive
 PSM provides ports for SD Card or USB2.0
• Files Accessible
 At the Controller using the Service Port
 At the HMI using USB or SD Memory Cards
 May be Accessible Remotely using mGuard Secure Internet
Cloud or Customer LAN Connected thru an mGuard Router
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Demonstration & Questions?

127
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Configuration Form

128
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PowerSync Training 4-Apr-2010

Exercise & Questions?

129
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Customization of PSMM Controllers


Type of Controller Sale Customization Commissioning Support
1. Distributor ASP
Standard MultiMaster None
2. Capstone Service
Controller (Site Configuration Only)
3. Capstone Engineering
1. Distributor ASP
MultiMaster Controller with Power or Flow Meter 2. Capstone Service
Applications Customization Graphics (e.g. one-line) 3. Capstone Applications
BOP (e.g. fuel skid) 4. Capstone Engineering
Custom Modbus Tables 1. Distributor ASP
MultiMaster Controller with Customer Control Logic 2. Capstone Service
Distributor Customization
3. Capstone Engineering

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PowerSync Training 4-Apr-2010

Customizing PowerSync MultiMaster


 PowerSync MultiMaster Intended for Customization
(PowerSync Master Not Designed for Customization)
 Space for additional I/O
 Full Function Industrial PC with 15” Color Touch Panel Display

 Customization done by Capstone


 Same process as currently used for CLC, except formal quote will be required (not
just a blanket 40 hours to start)
 Expect predefined screens and functions will reduce need for Customization.

 Customization by “Authorized System Integrators”


 Capstone training for selected distributors to use the Phoenix tools and
understand the existing PowerSync solution so that additional functions and/or
graphics can be added.
 Critical PLC Function Blocks will not be customizable

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Phoenix PLC & HMI Software


 PCWorx Development SW for 3050 PLC
 One programming software solution for all
Phoenix Contact controllers

• VISU+ Development SW for HMI


– Full SCADA (Supervisory Control And Data
Acquisition) function with visualization, trend
representation, and alarm management

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PowerSync Training 4-Apr-2010

PCWorx Supports Multiple Industry-Standard


Development PLC Programming Languages

Software PowerSync Controllers Use:


Structured Text and
Function Blocks

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VISU+ Graphical Tools for Data Visualization


Scripts for Navigation and Special
Development Data Handling (e.g. Sorting Event
Software Logs)
Built-in Logging and Trending
Functions
Example Custom Graphical Screen

PowerSync Controllers Use:


 Pre-defined Screens to limit
need for Customization
 Scripting to Facilitate
Viewing, Make Navigation
Easy, and Limit the Number
of Active Data Tags
 Additional Custom Screens
can be added
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PowerSync Training 4-Apr-2010

Example & Questions?

135
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Seamless Transfer Overview


• C200 & C1000 Products
• Requires:
 Latest Microturbine HW and SW
 New PowerSync Controllers
 External Synchronizing Relay (SEL-700GT)
 Electrically Operated Breaker with Aux Contact
 Remote I/O Modules (SEL-2505)
• Switch between GC and SA Modes in <1ms
• Capability is Standard with PowerSync Controllers

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Major System Components

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Major Component Functions


• Circuit Breaker Auxiliary Contact & SEL-2505 I/O
 Auxiliary Contact Indicates Main CB position (open or closed)
 SEL-2505 Remote I/O signals CB positon to MT’s
 Microturbines use CB position input to seamlessly switch between GC & SA Modes
• SEL-700GT Synch Relay
 Communicates voltage, frequency, and phase angle information to Capstone Controller
 Controls Circuit Breaker reclosing based on measured voltages and permissive signal
from Capstone Controller
• Capstone PowerSync MultiMaster or Master Controller
 Adjusts Microturbine voltage output to assure proper conditions before reconnecting to
the Utility
 Communicates Circuit Breaker open/close signals to SEL-700GT Relay based on
Operator input and measured voltages

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PowerSync Training 4-Apr-2010

Microturbine Sensing Circuit


24Vdc LCM Sensing Circuit
in each MT (example 3
bays)

Parallel (Star) Connections


to CB Position Contact

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SEL-700GT Relay

to
Microgrid
• Full-Function Utility-Grade Relay
• Seamless Transfer uses:
 25 Sync Check, 59/27 Voltage, and 81 Frequency Functions
 Voltage/Frequency/Phase Angle Sensing thru Modbus TCP
 Breaker Control thru Modbus TCP
• Can act as Power Meter with Optional CT’s
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PowerSync Training 4-Apr-2010

SEL-2505 Remote I/O


Digital Inputs

Digital Outputs

Multimode Fiber

• Utility-Grade High Speed Signal Transfer (10ms)


• Seamless Transfer uses the pair to:
 Transfer Main CB Position to Microturbines
 Monitor Health of Communications Signals
 Isolate MT LCM Control Voltage from Switchgear Voltages

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Transition Scenarios
Type of Transition
Grid Connect to Stand Alone to
Stand Alone Grid Connect

User Command through the Capstone User Command or Automatic


Controller Reconnection after a Utility Fault
Stable
(automatically starts all available (includes stability check & reconnect
Utility microturbines prior to transfer) delay)
Source
Condition
Protective Relay Trips
N/A
Main Circuit Breaker
Faulted (stability check prevents reconnecting to
(time delay according to protective relay
faulted source)
settings)

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PowerSync Training 4-Apr-2010

GC to SA Transfer – Stable Utility


• Operator Initiates Action thru Capstone Controller
• Capstone Controller
 Starts All Available MT’s to Prepare for Picking Up Load
 Issues Circuit Breaker OPEN Command to SEL Relay
• SEL 700GT Relay
 Sends OPEN (Trip) Command to Circuit Breaker
• Circuit Breaker
 Opens contacts to isolate Microgrid from Utility
 Auxiliary Contacts indicate status change to Microturbines
• Microturbines
 Briefly continue providing power in GC Mode
 Transition from GC to SA Mode within 1 ms

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Example 1 Transfer from Grid


C200 Under Test

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PowerSync Training 4-Apr-2010

Example 2 Transfer from Grid


C200 Under Test

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SA to GC Transfer – Stable Utility


• Operator Initiates Action thru Capstone Controller
• Capstone Controller
 Checks for Utility Voltage Stability & Times Reconnect Delay
 Adjusts Microturbine Voltage output to match Utility Frequency & Phase Angle
 Issues Circuit Breaker CLOSE Permissive signal to SEL Relay
• SEL 700GT Relay
 Confirms Voltage synchronism, then issues CLOSE command
• Circuit Breaker
 Closes contacts to reconnect Microgrid to Utility
 Auxiliary Contacts indicate status change to Microturbines
• Microturbines
 Briefly continue providing power in SA Mode
 Transition from SA to GC Mode within 1 ms
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PowerSync Training 4-Apr-2010

Example Transfer Back to Stable Grid


C200 Under Test

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Four Step
Reconnect Logic

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PowerSync Training 4-Apr-2010

GC to SA Transfer – Faulted Grid


• Fault Occurs on Utility
• SEL 700GT Relay Responds to Voltage/Frequency
 Sends OPEN (Trip) Command to Circuit Breaker
• Circuit Breaker
 Opens contacts to isolate Microgrid from Utility
 Auxiliary Contacts indicate status change to Microturbines
• Microturbines
 Briefly continue providing power in GC Mode
 Transition from GC to SA Mode within 1 ms
 If turbines do not experience a severe fault, power output continues in SA Mode
 If turbines experience a severe fault, system may temporarily stop producing
power and then return to SA Mode operation.

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Example Transfer from Faulted Grid


C600 Under Test

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Example Transfer from Faulted Grid


C600 Under Test

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Example Transfer from Faulted Grid


C200 Under Test Example 180kVA Load with Voltage Sag to 40%
Grid Connect Stand Alone
600

MT Current
500 Sag to 40% Voltage
Load Current

400

300

200

100

-100

-200

-300

-400

Circuit Breaker Aux Contact


-500
-0.05 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
Time [seconds]

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Realities of a Faulted System


• Response to Utility Grid Faults Takes Time
 SEL-700GT time delays (e.g.100ms)
 LV or MV Circuit Breaker Response (3 to 5 cycles)
• Microgrid Loads Will Experience Fault
Conditions until Isolated
• Most Utility Voltage Sags are Not Severe

EPRI Study example:


50 Events less than 10% sag
18 Events 30% or more sag

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Application Guidance
• Set SEL-700GT for Appropriate Response
 Fast response best for loads, but may cause nuisance operation
 Slow response avoids nuisance trips, but not best for all loads
 Requires understanding of load sensitivity and typical site faults
• Assure Adequate Generating Capacity
 PowerSync GC Dispatch Control provides Spinning Reserve setting
 Set GC Power Demand according to expected SA load (e.g. run all Available
microturbines or use Load Following with GC Spinning Reserve)
• Work with End User to Set Proper Expectations
 Define “protected” load characteristics & review site fault history
 Seamless Transfer capability can significantly improve, but not completely
eliminate, all potential load disturbances

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PowerSync Control Screen Example

View Status
of Reconnect
Process

Manually
Initiate
Reconnect
Control
Control Priority
(Admin in this example)

Control Screen
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Main Breaker SEL-700GT


Connections Grid PT Connections
Protective Relay
(Wye or Open Delta)

Main CB with SEL-2505


Trip/Close Coils & Remote I/O
Aux “a” Contact

CT Connections
(Optional)

Load PT
Connections (Wye or
Open Delta) Fiber to
Second
CAT6 Cable to Master or MultiMaster SEL-2505
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Example C1000S
Connections LCM Sensing
Circuit PowerSync Master
Controller

SEL-2505
GC & SA
Remote I/O
Enable Inputs

CB Position &
Alarm Inputs
to PLC

SEL-2505
Remote I/O
at Main CB

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PowerSync Space for Seamless Transfer


Connections Remote I/O Module

Example
PowerSync Master
Controller

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Demonstration & Questions?

159
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QUESTIONS?

FINAL EXAM

160
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Thank You

www.capstoneturbine.com
161
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