APM802 Controller

Kohler Singapore Pte Ltd │ April 2014

Introduction
Controllers Evolution

1988 1994 2004

 Launch of the  Launch of the  Launch of the Kerys
Process 1 Process 2  Color touch screen
 Synchro / load sharing  Integrated synchro /  System made up of
devices and load sharing devices modules linked
protection relays from protection devices together by CANBus
3rd parties  1998 - Integration of  2010 – Launch of
regulation card in the regulation module
rack
 3
Controllers evolution

Advanced Power Management

(*) Advanced Power Management
Advanced management of Energy

 Continuity of the Kerys

 An intuitive interface due to a new
ergonomic tactile MMI.
 The best of technology
 Ethernet communication
 More powerful, faster, more available
USB ports
 New programming in LADDER language
4
APM802 Modules
System Structure
The APM802 is a modular system

BASE Module Module Module

MMI
Module I/O digital I/O ANA I/O TEMP

REGULATIO
N
APM802 Module
System New: MMI, Base, Redundant
Modules
PROTECTION
Module Existing: Regulation,
Protection, Digital I/O,
REDUNDANT
Analog I/O, Temperature
Module I/O modules
6
System Structure

MMI Module
Base module Digital Analog Temp
I/O I/O Module
Module Module

Ethernet Cable
CanBus Cable
Redundant module Regulation module Protection module
7
MMI Module
(Man Machine Interface)
The MMI provides the interface between the generator and
the user.
The ergonomics makes the use easier and allows better
comfort forFull
 Screen: the operator.
color, 100% touch
screen
 Adjustable lighting
 Size 12.1'' (30 cm)
 DC Supply voltage: 24VDC
 Conceived for generators
configurations:
 Temperature and oscillations
tested.
 Protected against dust and
moisture by varnished
tropicalization. 8
MMI Module

MMI Module –
Back Panel
9
MMI Module
Memories
MMI Built-in 1 GB (RAM) & 2 GB (FLASH, SQ card)
 The SQ card is a compact flash
 It is similar to the hard disk of the MMI
 The internal logic for the graphics are stored inside these
2 memories.
 Linux OS and parameters copied from the Base Module.

Note: USB port can be used to download the parameters,

carry out screenshots, firmware upgrade).
Not possible to upload parameters from this USB

NEVER REMOVE THE SQ CARD FROM THE MMI – THE MMI 10

Base Module
The heart of the APM802 system
 Executes the automatism (internal logic software and configuration
software)
 Manages the communications between the APM802 systems
 Manages the external communications (Modbus, Web, computer, tablets,
smartphones..)
 Memorizes up to 1000 stamped events (log, alarms/defaults, engine error
codes)
 DC power supply voltage: 24VDC
 Operating temperature: -20°C to
+70°C
 Compliant to CE Directives
 Predisposed UL

11
 Base module
Inputs and Outputs
 2 Analog Inputs
Batteries Shunt
(0-100mv=)
 1 Analog Input
Pick Up (70 VAC  2 Analog Outputs
max) (AO.0 to AO.1)
 24VDC Power  4 Resistive
Supply Input Inputs (RES 0
 24VDC Power  to RES 3) Inputs
3 Analog
Supply Output (AI.0 to AI.2)
(MMI)
 18 Digital
Inputs (DI.0 to
DI.16) &
Emergency  18 Relay
stop Outputs (DO.0
to DO.16) &
WDG
12
Base Module
Inputs
N° INPUTS: APM 802 – Generator BASE N° INPUTS: APM 802 - PC BASE
I0 Production Request/Remote start order I0 Remote start order
I1 Low water level alarm I1 Bus Bar voltage OFF
I2 Alternator Circuit breaker closed I2 Mains circuit breaker closed
I3 Alternator Circuit breaker open I3 Mains circuit breaker open
I4 Alternator Circuit breaker tripped I4 Mains circuit breaker tripped
Standby Circuit breaker closed (A651 and A661) or Free for
I5 assignment I5 Standby Circuit breaker open
Standby Circuit breaker open(A651 and A661) or Free for
I6 assignment I6 Standby Circuit breaker closed
Standby Circuit breaker tripped (A651 and A661) or Free for
I7 assignment I7 Standby Circuit breaker tripped
I8 DC battery charger Alarm I8 Auxiliary battery charger alarm
I9 Measurement circuit breaker tripped alarm I9 Bus Bar voltage ON
I10 Mains voltage failure I10 Mains voltage failure
I11 Redundant Ethernet Ring alarm or Free for assignment I11 Redundant Ethernet ring Alarm or Free for assignment
I12 Free for assignment I12 Free for assignment
I13 Free for assignment I13 Free for assignment
Mains circuit breaker closed (A651 and A661) or Free for
I14 assignment I14 Free for assignment
Mains circuit breaker open (A651 and A661) or Free for
I15 assignment I15 Free for assignment
Mains circuit breaker tripped (A651 and A661) or Free for
I16 assignment I16 Free for assignment
I17 Emergency shutdown activated   I17 Emergency shutdown activated
13
Base Module
Outputs
N° OUTPUTS: APM 802 – Generator BASE N° OUTPUTS: APM 802 – PC Base
O0 Alternator circuit breaker closing order O0 Standby circuit breaker closing order
O1 Alternator circuit breaker opening order O1 Standby circuit breaker opening order
O2 Generator available in AUTO O2 Mains circuit breaker closing order
O3 Common Alarms O3 Mains circuit breaker opening order
O4 Common Faults O4 Powerplant not available in AUTO
O5 Generator running O5 Common Alarms
O6 Water pre-heating Command O6 Common Faults
O7 Request for generator start O7 Top Sync autorization
O8 Request for generator stop O8 buzzer command
O9 Pre-excitation command O9 Manual mode
O10 Excitation command O10 Test Lamps
Standby circuit breaker (A651 and A661) closing order or Free for
O11 assignment O11 APM802 OK or override
Standby circuit breaker (A651 and A661) opening order or Free for
O12 assignment O12 Free for assignment
O13 buzzer command O13 Free for assignment
O14 Top Sync autorization O14 Free for assignment
O15 Mains circuit breaker closing order or Free for assignment O15 Free for assignment
O16 Mains circuit breaker opening order or Free for assignment O16 Free for assignment
O17 Watchdog   O17 Watchdog

14
 Base Module
Communication Ports

 4 Bus CAN
(N°1 to N°4)
 1 USB port
 1 Input SD card

 2 Ethernet Ports  1 Serial port RS 485

(N°1 and N°2) (inter
APM)
 1 Ethernet port N°3
 1 Ethernet
(external)
port N°4
(MMI)
15
Base Module
Communication Ports

Kerys APM 802

CAN Communication 4 4 - With 120 Ohms terminaison switch.
With the isolated CAN n°4 APM to APM.
Ethernet Communication 1 4
RS Series Communication 3 Isolated RS485 (galvanic insulation)
With 120 Ohms terminaison switch.
USB for USB memory stick - 1
SD memory card - 1
Numerical input (digital) 16 +Emergency 18
Digital output 16 18
Analog input 3 3 (+/-10V or +/-20mA including 1
isolated).
Analog output 1 2 (one +/-10V and one +/-20mA)
Input batteries shunt - measurements - 2
for charge alternator current or battery
charger.
16
Base Module
Memories
BASE Module: 256 MB (FLASH), 512 MB (RAM), 2GB (FLASH,
SD Card)

 SD Card stores the parameters:

 3 separated Internal logics (single GS, GS//GS, PC)
 Configuration (ladder, parameters, messages, wordings)
 SD Card stores also the events log (even though there are
stored in the RAM memory)
 FLASH memory is used for the Lunix OS.

Note: Not possibility to carry out any parameters

uploading or downloading from this USB port. 17
Regulation Module
The Regulation module manages
 Electrical measurements
 Speed and voltage regulations
 Synchronization/coupling/load sharing
 Power consignments (load setpoints)
 Generator, power plant and mains
 Electrical protections (13)

18
Regulation Module
Electrical Measurements
 Generator Voltage  Powerplant Generators
 Generator Current Voltage
 Generator KW  Powerplant Generators
Current
 Generator Power Factor
 Powerplant Generator KW
 Generator Kvar
 Powerplant Generators Pf
 Generator Frequency
 Powerplant Generators Kvar
 Harmonics (3,5,7) Generators
voltages  Powerplant Generators
frequency
 Harmonics (3,5,7) Generators
Currents  Harmonic (3,5,7) MAINS
Voltage
 Generators phases sensing
rotation  Harmonic (3,5,7) Powerplant
Currents 19
Regulation Module
Regulation & Synchronizing
 Synchronization and coupling
 Voltage and frequency regulations
 Active power (KW) and reactive power (Kvar) regulations
 Power-factor regulation
 Active power(KW) and Reactive power (Kvar) load sharing
by analog bus (so called “parallel lines” or “load sharing
lines”)
 Active power(KW) and Reactive power (Kvar) load sharing
by the Ethernet LAN cable between APM802 BASE modules
(generators to generators)
 Frequency and Voltage Droop (in manual mode)
20
Regulation Module
Electrical Protection
 The Regulation module has 13 built-in electrical
protections
 (ANSI 49) Thermal Image.
 (ANSI 50) Overcurrent alternator.
 (ANSI 27) Undervoltage alternator
 (ANSI 59) Overvoltage alternator
 (ANSI 81L) Underfrequency alternator
 (ANSI 81H) Overfrequency alternator
 (ANSI 32 PH) Max Active Power
 (ANSI 32 PQ) Max Reactive Power
 (ANSI 32 PL) Min Active Power
 (ANSI 32 RP) Reverse Active Power (Kw)
 (ANSI 32 RQ) Reverse Reactive power (Kvar) or loss of
excitation
 (ANSI 78) DF/DT
 (ANSI 78) Vector Jump

21
Regulation Module
Communication
 1 analog input for KW load sharing (//lines)
 1 analog input for Kvar load sharing (//lines)
 1 analog input external speed setpoint (GCR)
 1 analog output speed adjustment (engine control)
 1 analog output voltage adjustment (check out alternator)
 3 outputs relay:
 1: Top sync
 2: Protection Mains or GE
 3: Copy relay 1 or 2 or //line management
 1 RS45 connection for firmware upgrade and diagnosis
through website
 1 CAN BUS connection 22
Protection Module
The Protection module has the
following functions:
 Electrical protections (generator
set)
 Electrical protections (installation -
Mains)

23
Protection Module
Electrical Protection
 The Protection module has 9 additional protections on top of
those from the regulation module
 These electrical protections are used in medium voltage
application – especially when paralleling with the Mains
 9 additional protection:
 (ANSI 46) Max of component Maximum reverse reverses
component.
 (ANSI 50/51) Short circuit current
 (ANSI 51N) Homopolar current
 (ANSI 67) Directional shorts circuit current
 (ANSI 67N) Directional homopolar current.
 (ANSI 21) Min impedance
 (ANSI 51V) Shorts circuit with voltage holding
 (ANSI 64REF) Restricted earth
 (ANSI 64) Homopolar voltage

24
Additional Modules I/O
 The additional I/O modules manage the additional inputs
and outputs
Temperature Analog Digital

3 inputs for the

temperature 4 analog inputs 8 binary inputs
measurement 2 analog outputs 4 outputs relay 25
Redundant Module
 24VDC supply, protected from
the reverse polarities
 Tested from -20°C to +70°C,
vibration tested
 Ethernet cables Cat 5 or higher
category are recommended
 The length of Ethernet cable
should not exceed 100 M
Ethernet Ring Option – APM 802 communication redundancy
Pre-programmed module from SDMO factory
Dual power supply
Volt free contact for open to inform about Ethernet ring loop alarm
Available in several versions: Ethernet (5 ports) and Ethernet + Optical fiber
26
Redundant Module
 In a multiple generating sets APM802 allows
communication between all generator sets in the same
network
 In the event that a network link is broken, all
communication within the network is broken
 One solution is to have duplicate communication line
 Costly
 Higher maintenance
 Redundant modules allows full communications between
all generator sets in the same network even with 1 broken
link
27
Redundant Module

GS GS
1 2

APM802
Redundancy
Ethernet Ring

GS GS Master Panel
Redundanc
3 4 y
Module 28
Connectivity
Connectivity Between
Two APM802
Communication schematics between 2 APM802

MMI 1 MMI 2

Towards following
BASE 1 BASE 2 generators (up to
64 Generators)

Ethernet Ethernet
30
Connectivity Between
Two APM802
Principal communication
 Ethernet
 Maximum distance of
100m between 2
controllers

31
Connectivity With
Redundant Module
Redundancy communication schematics between 2 APM802

GS1 MMI 1 MMI 2 GS2

BASE BASE
1 2

Etherne
Redundan t Redundan
t Module t Module

Etherne 32
Connectivity With
Redundant Module
Principal communication
 Ethernet
 Ethernet Ring by Redundant
module
 Segments of 100m

Connectivity
 Available in any point of the ring
 Separated

33
Modbus
Modbus TCP/IP
 The supervision in Modbus TCP/IP is possible, via an
Ethernet link on the BASE module.
 This Ethernet link is configurable for the customer’s
installation

Modbus RS485
 The supervision in Modbus RTU is possible, via a link
RS485 on the BASE module.
 This is an isolated RS485 connection and configurable for
the customer’s installation.
34
Connectivity
Connection technologies of the APM802 bring an high
service level and a functional coherence to projects
Remote Access

Touch
Screen
firewall Control

Smartphone,
Laptop & Control Room
Tablet
35
Real Time Mobile Devices
Connectivity
Duplicate display from APM802 MMI to mobile devices via
VNC & internet connection

 Real-time
 Full controls & features
 Works for all brands of
computers, laptops,
tablets & mobile phones
 Works for all OS
 Allows monitor & control
of generator sets,
anywhere, anytime
36
Real Time Mobile Devices
Connectivity

Mobile
Phone

Ethernet Tablet

Ethernet
Wifi Router
Computer
37
Paralleling
Synchronizing Methods
 APM802 is capable of
synchronizing up to 64
generator sets and up GS1 GS2
to 8 utility mains
 2 methods are used
for synchronizing CB
M M CB
purpose between 1 2
generator sets
 Live bus BUSBAR
synchronizing
 Dead bus LOAD
synchronizing 39
Live Bus
Synchronizing Method
LIVE BUS Synchronizing
Initial states:
GS1 GS2 GS1 and GS2 not
running
GS1 in AUTO – CB1
Open

CB1 CB2 GS2 in AUTO – CB2

M M
Open

Busbar

Load 40
Live Bus
Synchronizing Method
Start
order
LIVE BUS Synchronizing
1- Start order to GS1
GS1 GS2 GS1 starts

M CB1 M CB2

Busbar

Load 41
 Live Bus
Synchronizing Method
Start
Nominal order
LIVE BUS Synchronizing
U
Nominal 1- Start order to GS1
F
GS1 GS2 GS1 starts - Increase of
voltage and frequency
2- Close CB1 (at nominal U
and F)
M CB1 M CB2

Busbar

Load 42
 Live Bus
Synchronizing Method
Start
Nominal order
Start
order
LIVE BUS Synchronizing
U
Nominal 1- Start GS1
F
GS1 GS2 2- Close CB1
3- Start order to GS2
GS2 starts - Increase of
voltage and frequency
M CB1 M CB2

Busbar

Load 43
 Live Bus
Synchronizing Method
Start
Nominal order Nominal
Start
order
LIVE BUS Synchronizing
U U
Nominal Nominal 1- Start GS1
F F
GS1 GS2 2- Close CB1
3- GS2 starts - Increase of
voltage and frequency
4- The nominal U and F are
M CB1 M CB2 reached

Busbar

Load 44
 Live Bus
Synchronizing Method
Start
Nominal order Nominal
Start
order
LIVE BUS Synchronizing
U U
Nominal Nominal 1- Start GS1
F F
GS1 GS2 2- Close CB1
3- Start GS2
4- The nominal U and F are
reached
M CB1 M CB2
5- Synchronize GS2
on GS1 in
progress Sync Scope

Busbar

Load 45
 Live Bus
Synchronizing Method
Start
Nominal order Nominal
Start
order
LIVE BUS Synchronizing
U U
Nominal Nominal 1- Start GS1
F F
GS1 GS2 2- Close CB1
3- Start GS2
4- The nominal U and F are
reached
M CB1 M CB2
5- Synchro GS2 with
busbar
6- Close CB2
Busbar

Load 46
Dead Bus
Synchronizing Method
DEAD BUS
Synchronizing (Busbar =
0VAC)
GS1 GS2
Initial states:
GS1 and GS2 not
running
GS1 in AUTO – CB1
Open
M CB1 M CB2
GS2 in AUTO – CB2
Open
No voltage on the
Busbar Busbar

Load 47
Dead Bus
Synchronizing Method
Start
order
Start
order
DEAD BUS Synchronizing
(Busbar=0VAC)

GS1 GS2 1- Start order sent

simultaneously on both GS1
and GS2
2- Close CB1 and CB2
M CB1 M CB2 3- Start diesel engines GS1 and
GS2
(the excitation of the
alternators are open)
Busbar => Increase of engine
speed
Load 48
Dead Bus
Synchronizing Method
Start
order
Start
order
DEAD BUS Synchronizing
(Busbar=0VAC)

GS1 GS2 1- Start order sent

simultaneously on both GS1
and GS2
2- Close CB1 and CB2
M CB1 M CB2 3- Start diesel engines GS1
and GS2
(the excitation of the
alternators are open)
Busbar => Increase of engine
speed
Load
4- Control speed GS1 and GS2 49
Dead Bus
Synchronizing Method
Start
order
DEAD BUS Synchronizing
(Busbar=0VAC)
1- Start order sent simultaneously
GS1 GS2
on both GS1 and GS2
Alternator Alternator
GS1 GS2 2- Close CB1 and CB2
Excitation Excitation
order order 3- Start diesel engines GS1 and
GS2
M CB1 M CB2 (the excitation of the
alternators are open)
=> Increase of engine
speed
Busbar 4- Control speed GS1 and GS2
5- >1450 tr /mn, Excitation
Load alternators of GS1 and GS2 50
Dead Bus
Synchronizing Method
Nominal Nominal
Start
U
order
U DEAD BUS Synchronizing
(Busbar=0VAC)
1- Start order sent simultaneously
GS1 GS2
on both GS1 and GS2
Alternator Alternator
GS1 GS2 2- Close CB1 and CB2
Excitation Excitation
order order 3- Start diesel engines GS1 and
GS2
M CB1 M CB2 (the excitation of the
alternators are open)
=> Increase of engine
speed
Busbar 4- Control speed GS1 and GS2
5- >1450 tr /mn, Excitation
Load alternators of GS1 and GS2 51
Dead Bus Synchronizing -
Advantages
Progressive synchronization
Fast response on demand: Availability
between generator sets with
of electrical power with the multiple
the increase of voltage
paralleled generator sets. The
=> Less risk crash alternator
generator sets reach their nominal
synch, the circuit breaker
voltages and speed in approximately
damage and eventually the
10 seconds
diesel engine damage during
Advantages the synchronizing sequence.
In Medium voltage application, Possibility to energize a step up
using step up transformer – The transformer of bigger capacity
in-rush current of the than the generator set.
transformer is null as this
current increases with the
voltage build up.

52
Built-In
Configurations
APM802 For Island
Power Station
 Up to 64 generator sets in parallel
 With watt metric (generator) management A633 configuration
 In Low Voltage as well as in Medium
voltage
 In Prime power and Emergency Standby
modes

GS1 GSn ( up to 64) 54

A633 Configuration
TC: X/5A CL0.5
GS1 GS2

3Ph + N Regulation Regulation 3Ph + N

Module 3Ph 5VA Module
Bus Can 3 Bus Can 3

Base ETHERNET Cable Base

M Module Module M
Ethernet Ethernet

64 GS Max
LOAD
55
APM802 For Power plant
Parallel To The Mains
A635 configuration

The PC Master Each generator

panel  Control the generator
 Control the power set and the circuit
plant breaker
 Supervises the Mains  Ensures the check
and manages the out and the diagnosis
multiple Mains (8) of the engine
 Manages the control  Protects the
of the ATS generator set
56
A635 Configuration

CT: X/5A 0.5 10VA CT: X/5A 0.5 10VA Mains

CT: X/5A 0.5 10VA
Regulation Regulation Regulation
3Ph + N 5VA Module 3Ph + N 5VA Module Module 3Ph + N 5VA
Bus Can 3 Bus Can 3 Bus Can 3

Base Base Base

M Module 1 M Module 2 Module PC
Inter Base (Ethernet)
Ethernet Ethernet Ethernet

64 Sets Max
X Regulation modules for X Grid(s) Bus Bar CT
option M M

LOAD 57
APM802 for Single
Generator set
The single generator set in parallel A651, A661, A641, A642
to the Mains: Configurations

 Up to 8 Mains
 In Low Voltage as well as in
Medium voltage
 Manages the control of the ATS.
 In prime power and in
Emergency Standby applications

58
A641 Configuration
TC: X/5A 0.5
10VA
MAINS

Regulation
Module 3Ph + 5VA
3Ph + N 5VA Bus Can 3

M Base
module
Ethernet

A641
Generator set permanent
synchronize with mains LOAD 59
A642 Configuration
TC: X/5A 0.5
10VA
MAINS
TC: X/5A 0.5
10VA
Regulation
Module 3Ph + 5VA
3Ph + N 5VA Bus Can 3

M Base
module
Ethernet

A642
Generator set permanent
synchronize with mains LOAD 60
A651 Configuration
TC: X/5A 0.5
10VA
Mains
TC: X/5A 0.5
10VA
Regulation
Module 3Ph + 5VA
3Ph + N 5VA Bus Can 3

Optional Base
module
Ethernet

M M

A651
Short term synchronization
with mains with ATS LOAD 61
A661 Configuration
TC: X/5A 0.5
10VA
Mains
TC: X/5A 0.5
10VA
Regulation
Module 3Ph + 5VA
3Ph + N 5VA Bus Can 3

Optional Base
module
Ethernet

M M

A661
Generator set permanent
synchronize with mains with LOAD 62
Integration
Mounting Panel
Options for
APM802

Floor
Mounted
Cabinet
Skid Mounted
Cabinet

Skid Mounted
Panel 64
New Ergonomic
For Skid Mounted
Panel

Adjustable MMI
Panel
 Better
ergonomic
 Reduce light
reflection 65
Questions ?
Thank You