Migration DSE8610 / 8620 to COMPACT Prime_En_V1

The CRE Technology team would like to thank you for trusting our expertise and investing in a product developed in France.

We have created this application note to help you during the migration of your DSE86xxMKII modules to GENSYS COMPACT Prime/Mains.

The application note is based on the default configuration of the controllers in order to prevent installation mistakes, please make sure the wiring corresponds to your installation before commissioning.

You will find all the technical documentation concerning the Gensys Compact Prime / Gensys Compact Mains on the CRE Technology website. 

TYPICAL WIRING DIAGRAM – GENSYS COMPACT PRIME

You can download the attached file about the Typical wiring diagram (PDF format)

OPERATIONNAL MODES – GENSYS COMPACT PRIME

The GENSYS COMPACT PRIME can be configured and controlled with the front panel, which is separated into two parts:

1.  The top end and middle part: are dedicated to the navigation, monitoring, and measurement display.

2.  The bottom end part: is dedicated to the 3 functioning modes selection:

• AUTO - This mode makes the GENSYS COMPACT PRIME operate the installation in a fully automatic mode according to its settings and configuration, external action to start: “remote start digital input” or TCP ModBus.
• TEST - This mode simulates the start of the Auto mode with the requested sequences, to exit from the TEST mode, simply press AUTO again or press MANUAL mode.
• MANU - This mode allows you to manage your installation with the front panel buttons manually: you will be able to start/stop the generator, open/close the breakers while still benefiting from the active protections of the GENSYS COMPACT PRIME and the automatic synchronization and load/unload sequences.

MENUS – GENSYS COMPACT PRIME

Once the GENSYS COMPACT PRIME is switched on, you can access the menu on 3 different levels (to access the password page, press ESC or ENTER.):

• Level 0: No password is required, just press «ENTER» to access the display.
• Level 1: Just press «ENTER» to go to the Display menu. Press «↓» to select «configuration» or «system» of the GENSYS COMPACT PRIME. Press «ENTER» to switch to password mode. Press «↑» to change the character; press «→» to move to the next character. The level 1 password is «1»

NOTE: The Level 1 password gives you access to the minimum settings recommended to start your commissioning on your power plant. This level “1” is equivalent to “standard mode” on the i4Gen Suite software.

• Level 2: Just press «ENTER» to go to the Display menu. Press «↓» to select «configuration» or «system» of the GENSYS COMPACT PRIME. Press «ENTER» to switch to

password mode. Press «↑» to change the character; press «→» to move to the next character. The level 2 password is «1234».

NOTE: The level 2 password gives you access to all settings to commission your power plant. This level “2” is equivalent to “advanced mode” on the i4Gen Suite software. 

For complex settings, which are not available through the front panel of the module, you can use i4Gen Suite software (Analogue inputs, Easyflex, Scheduler, etc ..).

THE DIFFERENT MENUS WILL APPEAR AS FOLLOW

REWIRING 8610 Vs. Gensys Compact Prime

Terminal used by DSE8610MKII (Yellow) vs GENSYS COMPACT PRIME terminal.

Follow the standard wiring schematics of COMPACT Prime  for more instructions

NOTE

Before the commissioning or the operation of your equipment, please read carefully the user’s manual and other related documentation. Engines, turbines, or any other type of Generator must be equipped with protections (overspeed, temperature, pressure… depending on your installation).

We also offer personalized and specific training on our product range and software, as well as additional services such as: onsite support, application engineering, or specific support.

Carefully apply the safety instructions. Any misuse of your equipment can lead to human or machine damages.

COMMISSIONING 

In Manu mode: Start/Stop the engine, and check protections (oil pressure, water temp, emergency stop, etc …). Open and close the generator breaker. Apply some load, and check that kW power are positive on each phase. Connect the controller analog outputs on the speed governor and AVR products, and execute the Easy Calib function to control and adjust automatically the 2 analog signals.

• Check that you have the right and accurate nominal frequency and nominal voltage. By increasing/decreasing the speed manually, check that you have a range of +/- 2,5 Hz. By increasing/decreasing the voltage manually, check that you have a range of +/- 8%.
• Disconnect the breaker relay output of the controller. Apply synchronization and check if frequency, phase, and voltage differences are within the expected limits.
• Paralleling can be tested, and stability can be adjusted.
• After commissioning, products can be switched to AUTO mode.

CONTROL LOOPS ADJUSTMENT

To adjust these parameters, we offer, on the same screen, the real time curves visualization of parameter setpoint and measurement.

These 2 curves will help you to adjust PID for global stability. It is available for synchronization (Frequency, phase, and

voltage), and power control (kW/kVAR).

• With level 1 of the controller (standard mode with i4Gen Suite), you have access and you can set the global gain G.
• With level 2 of the controller (advanced mode with i4Gen suite), you have access and you can set the proportional P, integral I, and derivative D:
  • Increase P value to have a measure curve close to the setpoint curse, without hunting.
  • Increase I to decrease the static error (difference between setpoint and measure), without slow hunting.
  • Only if necessary, increase D, for oscillation attenuation.

TYPICAL WIRING DIAGRAM – GENSYS COMPACT MAINS

You can download the attached file about the Typical wiring diagram (PDF format)

OPERATIONNAL MODES – GENSYS COMPACT MAINS

The GENSYS COMPACT MAINS can be configured and controlled with the front panel, which is separated into two parts:

1.  The top end and middle part: are dedicated to the navigation, monitoring, and measurement display.

2.  The bottom end part: is dedicated to the 3 functioning modes selection:

• AUTO - This mode makes the GENSYS COMPACT MAINS operate the installation in a fully automatic mode according to its settings and configuration, external action to start: “remote start digital input”, Mains failure” or TCP ModBus.
• TEST - This mode simulates the start of the Auto mode with the requested sequences, to exit from the TEST mode, simply press AUTO or press MANUAL mode.
• MANU - This mode allows you to manage your installation with the front panel buttons manually: you will be able to start/stop the generator, open/close the breakers while still benefiting from the active protections of the GENSYS COMPACT MAINS and the automatic synchronization and power management sequences.

MENUS – GENSYS COMPACT MAINS

Once the GENSYS COMPACT MAINS is switched on, you can access the menu on 3 different levels (to access the password page, press ESC. or ENTER):

• Level 0: No password is required, just press «ENTER» to access the display.
• Level 1: Just press «ENTER» to go to the Display menu. Press «↓» to select «configuration» or «system» of the GENSYS COMPACT MAINS. Press «ENTER» to switch to password mode. Press «↑» to change the character; press «→» to move to the next character. The level 1 password is «1».

NOTE: The Level 1 password gives you access to the minimum settings recommended to start your commissioning on your power plant. This level "1" is equivalent to «standard mode» on the i4Gen Suite software.

• Level 2: Just press «ENTER» to go to the Display menu. Press «↓» to select «configuration» or «system» of the GENSYS COMPACT MAINS. Press «ENTER» to switch to password mode. Press «↑» to change the character; press «→» to move to the next character. The level 2 password is «1234».

NOTE: The level 2 password gives you access to all settings to commission your power plant. This level “2” is equivalent to “advanced mode” on the i4Gen Suite software. 

For complex settings, which are not available through the front panel of the module, you can use i4Gen Suite software (Analogue inputs, Easyflex, Scheduler, etc ...)

THE DIFFERENT MENUS WILL APPEAR AS FOLLOW

REWIRING 8620 Vs. Compact Mains

Terminal used by DSE86200MKII (Yellow) vs GENSYS COMPACT MAINS terminal.

Follow the standard wiring schematics of COMPACT Mains for more instructions

NOTE

Before the commissioning or the operation of your equipment, please read carefully the user’s manual and other related documentation. Engines, turbines, or any other type of Generator must be equipped with protections (overspeed, temperature, pressure… depending on your installation).

We also offer personalized and specific training on our product range and software, as well as additional services such as: onsite support, application engineering, or specific support.

Carefully apply the safety instructions. Any misuse of your equipment can lead to human or machine damages.

COMMISSIONING 

• In Manu mode: Start/Stop the engine, and check protections (oil pressure, water temp, emergency stop, etc …). Open mains breaker and close generator breaker. Apply some load on the generator, and check that kW power are positive on each phase.
• Connect the controller analog outputs on the speed governor and AVR products, and Execute Easy Calib function to control and adjust automatically the 2 analog signals.
• Check that you have the right and accurate nominal frequency and nominal voltage. By increasing/decreasing manually the speed, check that you have a range of +/- 2,5Hz. By increasing/decreasing manually the voltage, check that you have a range of +/- 8%.
• Disconnect the breaker relay output of the controller. Apply synchronization, and check if frequency, phase, and voltage differences are within the expected limits. Apply the same procedure to control the Mains breaker.
• Mains paralleling can be tested, and stability can be adjusted.
• After commissioning, the product can be switched to AUTO mode.

CONTROL LOOPS ADJUSTMENT

To adjust these parameters, we offer, on the same screen, the real time curves visualization of parameter setpoint and measurement.

These 2 curves will help you to adjust PID for global stability. It is available for synchronization (Frequency, phase, and

voltage), and power control (kW/kVAR).

• With level 1 of the controller (standard mode with i4Gen Suite), you have access and you can set the global gain G.
• With level 2 of the controller (advanced mode with i4Gen suite), you have access and you can set the proportional P, integral I and derivative D:

• Increase P value to have measure curve close to setpoint curse, without hunting.
• Increase I to decrease the static error (difference between setpoint and measure), without slow hunting.
• Only if necessary, increase D, for oscillation attenuation.

Notes:

** All I/O are negative (-) to active on COMPACT

* EQUIPOTENTIALITIES: It is important to respect the following equipotential schematic with EARTH adequate wiring.

Potential differences between Neutral, Ground, Common CT, Battery negative and 0VDC COMPACT module could create an undesired current going through the COMPACT module, and the following problems can occur:

• Wrong voltage measurement & display values

• Wrong current measurement and display values

• Wrong analog inputs measurement and display values

•  Damage of the controller in some situations

All earth points must be correctly connected and measurement of 0VDC has to be observed between them

CONFIGURATION SOFTWARE:

i4Gen Suite for COMPACT, downloadable free software from

PC CONNECTION WITH I4GEN SUITE SOFTWARE 

Power the controller. Connect the Ethernet port (RJ45-LAN) of your computer to the Ethernet port of your controller. To be able to establish communication between the i4Gen Suite software and the controller, the network addresses of the devices must be configured:

1. For PC network configuration, please refer to your Windows network settings.

2. The network configuration of the controller is to be done via the front panel of the controller or with the i4Gen Suite software.

3. The network configuration of the devices must be compatible: the default IP address on CRE TECHNOLOGY controllers is: 192.168.11.1

INSTALLATION OF THE I4GEN SUITE SOFTWARE

Download the latest version of the software on our website

CONTROLLER SUPERVISION (Visualization of all parameters)

CONTROLLER DYNAMIC SETTINGS (Parameters settings with engine running)

CONTROLLER STATIC SETTINGS (Parameters setting with engine stopped)