1

Genset
Training
GT_Session1.ppt
Session 1
CW170 & 180 Configuration Overview,
Genset Wiring,
Sensors &
Genset Mounted Enclosures.
Session 1 - System Introduction.
2
Genset
Training
GT_Session1.ppt
CW170 - Diesel Genset Arrangement
Alternator
PC Based
HMI
Woodward
Actuator
Genset Control Panel
Engine
sensors
sensors
3-Phase AC Supply
by Customer
Cense Data & Fault Codes
Full Governor Control by PCC
Genset CB
Control by PCC
RS-485
I/O
RS-422
RS-232
PLC
Customer
Supplied
Interconnect
Wiring
Supply to prelube, wtr circ,
clean fuel spill pumps,
eng & alt heaters
Control Batteries
& Charger
Power Command Control
AC
Terminal
Box
DC
Terminal
Box
sensors
CENSE
(Level 0)
3
Genset
Training
GT_Session1.ppt
PC Based
HMI
Woodward
Actuators (2)
Genset Control Panel
Engine
sensors
Control Batteries
& Charger (10A)
sensors
Genset CB
Control by PCS
Fault Codes & Data
via Modbus Network
J1939 Network
MCM-700
sensors
SSM-558 (2)
CCD/PDM (2)
sensors
Power Command Supervisor
RS-485
I/O
RS-232
RS-485
PLC
AC
Terminal
Box
Plant
Interfacel
Box
3-Phase AC Supply
by Customer
Cust.
Supplied
Interconnect
Wiring
sensors
Alternator
Supply to prelube, wtr circ,
engine & alt heaters
CENSE
(Level 1)
Synchronizing, kW Load Sharing,
and Utility Paralleling Load Control
Speed Bias by PowerCommand
Supervisor (PCS)
(Base Governor by MCM-700)
CW180 - Gas Genset Arrangement.
Engine
Batteries
& additional
Charger (20A)
1-Phase AC Supply
by Customer
Fully integrated system, all modules are now
connected. The MCM700 has start/stop/
venting control for the engine and it can relay
fault information from any module to the HMI
via a modbus link.
New CW180 - Production Release 1998
Changes from Field Test Release (changes shown in RED):
More sensor data available to user
Enhanced governor features of MCM-700
Data available via standard Modbus network
More system fault codes available to user
4
Genset
Training
GT_Session1.ppt
Protocol and Interface Standards
Modbus is the Industry standard microprocessor communications package protocol.
Modbus communication is used to communicate between PCC / PCS,MCM700,HMI and the PLC.
Modbus operates on RS422 or RS485 Interface connections.
RS 232 INTERFACE
GND GND
TX
RX RX
TX
TX1 TX1
RX1
RX1
RX2 RX2
TX2 TX2
9 PIN D
Connectors
9 PIN D
Connectors
RS 422 INTERFACE
RS232 Interface Standard connection
Error checking by multi transmit ( parity check), if
not received shuts down.
Max communicating distance 5 mtrs.
RS422 Interface Standard connection
Error checking by collision detection and parity
check, both lines work in parallel allowing higher
power transmission.
Max communicating distance 15 mtrs.
RS485 Interface Standard connection
RS485 uses the new RS222 connection ( 2 wire
as RS232 ) which is then electrically enhanced to
give RS422 type operation.
Baud rate for a RS232 / 422 interface is 2,400 to 19,600.
5
Genset
Training
GT_Session1.ppt
CW 170/180 Genset Harness
The following shows the arrangement of the connecting OEM harnesses around the genset.
The arrangement is similar for both CW170 and CW180 gensets.
The harnesses are pre-fabricated and are not forseen as being serviceable, however, at all main exits from the
trunking draw wires are provided to install additional or replace broken connections.
Genset Left Hand Side Genset Right Hand Side
AC Harness DC Harness or low voltage supplies
Plant Interface Box
AC Auxiliary Box Alternator Auxiliary Box Engine Interface Box
A-Bank side
B-Bank side
6
Genset
Training
GT_Session1.ppt
OEM Harness Build Up.
The genset wiring is made up of four main component
parts;
DC harness arrangement - aluminium structure.
{This provides the interface between the low voltage or
mAmp signals to and from the GCP and genset via the
plant interface box}.
AC harness arrangement - aluminium structure.
{This provides the interface between the genset AC
auxiliaries and their respective control box.
Note : 380 - 480, 3 phase voltage and current is present }.
AVR and PT/CT harness - flexible plastic structure.
{Carries the PCC/PCS derived PWM 12 volt dc 3.0kHz
signal for voltage regulationalong with the 18 volt ac
PT/CT references }.
Alternator heater harness - flexible plastic structure.
{Carries the ac voltage to the alternator heater from the
AC aux box.
Note : Danger, single phase high AC voltage is present.}.
7
Genset
Training
GT_Session1.ppt
CW180 Sensor Harness Partitioning.
GP01 - High Gas Pressure MCM700 Harting Connector
GP02 - Low Gas pressure
GV1 - FSO Vent Valve
GV2 - FSO Downstream
Block Valve
GV3 - FSO Upstream
Block Valve
(GV1-3 are position Switches)
To Plant Interface Box
MX15 - PCS Mag Pick-up To AC Auxiliary Box
MX10 - Baring Gear Engaged
AP01 - Start Air Pressure
FL03 - Dirty Oil Level Tank High
FL14 - Dirty Oil Level Tank High/High
Flywheel End
DC Harness AC Harness
LL02 - Oil Sump Level Low
WT04 - Coolant Heater Control
LP01 - Oil Pressure (Prelube)
LT03 - Lube Oil Temperature
(if fitted)
MX52-1 Engine Pre-Heater
MX52-2 Engine Pre-Heater
MX60 - Oil Priming Pump
MX61 - Coolant Circ Pump
( Alt heaters supplied from
AC box in separate loom)
NOTE : These
are separate
genset
harnesses, the
engine harness
is separate.
8
Genset
Training
GT_Session1.ppt
CENSE Interface LL02 - Sump Oil level
FT01 - Fuel Oil Temperature MX52-1 Engine Pre Heater
LT01 - Lube Oil Temperature MX52-2 Engine Pre Heater
LP01 - Lube Oil Pressure (Prelube)
Dirty Fuel Float Switch LP02 - Lube Oil Pressure (PCC)
Clean Fuel Float Switch WT02 - HT Water Temp (PCC) MX59 Clean Fuel Spill
Pump
To Plant Interface Box
A-ET19 - Exhaust Gas Temp A MX60 Oil Priming Pump
B-ET19 - Exhaust Gas Temp B MX61 Coolant Circ Pump
SS01 - Electric Start SOV
(If fitted - in engine harness on 180)
AV02 - E/Stop Sov
AP02 - Stop Air Pressure
MX10 - Baring Gear Engaged
MX15 - PCC Mag Pick-Up To AC Auxiliary Box
AP01 - Start Air Pressure
AV01 - Start SOV
ProAct Diver Module
Flywheel End
DC Harness AC Harness

CW 170 Sensor Harness Partitioning.
NOTE : These
are separate
genset
harnesses, the
engine harness
is separate.
( Alt heaters supplied from
AC box in separate loom)
9
Genset
Training
GT_Session1.ppt
CW 170 AC Auxiliary Box ( B bank side)
Photo - 170 AC Box
Control Components include :
Engine Heaters, MCB 1 & 2, rated 6kW ea,
Alternator Heater, MCB 3, rated 300w,
Circulation Pump, MCB 4, rated 250w,
Clean Fuel Spill Pump, MCB 5, rated 550w,
Pre-lube Pump, MCB 6, rated 3.5kW,
Undervoltage Protection Unit, MCB 7
for above components
This cubicle shall be customer supplied :
Standard format is 3 Phase 4 wire.
An additional circuit breaker is provided which
allows the 10 amp single phase GCP supply to be
routed from this box.
Note: 3 phase 3 wire option is fitted with an
additional circuit breaker for the single phase
alternator heater.
Terminal Blocks :
Control wiring ( Grey) & Power Connections ( Orange ).
10
Genset
Training
GT_Session1.ppt
Show Close up of MCB in AC Box
AC Auxiliary Box MCB Arrangement.
Main Isolation
Aux switch
(OF) contact
breaker position.
on/off status on HMI
Alarm switch
(SD) contact
trip condition
Main Isolation
Aux isolation
and trip
switch
Set Points :
Engine Heater #1 - MCB1 - 3.2 Amps
Engine Heater #2 - MCB2 - 3.2 Amps
Alternator Heater - MCB 3 - 3.2 Amps
Circulation Pump - MCB4 - 0.7 Amps
Clean Fuel Spill Pump - MCB5 - 1.6
Amps (170 Diesel only)
Prelube Pump - MCB6 - 6.8 Amps
11
Genset
Training
GT_Session1.ppt
CW 180 AC Auxiliary Box ( B bank side)
Control components are the same as the CW170
with the exception of the Clean Fuel Spill pump which is
not required on the 180.
Using the previous kW ratings (16.05 total for 180) the
current consumption can be calculated thus :
( NOTE: KW to HP x by 1.34 and HP to KW x by 746)
Current = 746 x Horsepower (HP is kW x 1.34)
1.732 x Volts x Efficiency x Power Factor
For a CW170 running 415 V @ 0.8 P.F Total Aux load:
Current = 746 x (16.05 x 1.34) = 28 ( approx 30 A)
1.732 x 415 x 1 x 0.8
Current will vary from site to site depending upon
CW170 or CW180 genset,
site voltage,
efficiency and
power factor.
Photo of CW 180 AC Box
12
Genset
Training
GT_Session1.ppt
CW170/180 Plant Interface Box (A bank side)
CW 180 Plant Box Photo
These enclosures provide the main interface
between the GCP and the genset. Whilst they
are similar in construction care should be taken to
determine the correct connections.
Refer to the drawings GCP180-G4A for gas sets
and GCP170-G4A for diesel sets along with their
associated schematics for confirmation.
The kW transducer shown in the photograph is
only utilised on the CW180 product.
This is the kW source for the MCM700 load
reference 4 - 20 mA. ( for torque over boost calc).
It is a 3 phase 4 wire unbalanced load unit.
It is pre-calibrated to allow the panel control
system CT s to be connected in series.
Two models are available
for HV sets- voltage input routed via a PT,
for LV sets - direct voltage input up to 480V.
Only fitted to 180 - Terminals for
separate 20A charger ( Proact drivers)
NOTE: PCC/PCS also calculates KW (Theoretical) but can not
access this KW signal for use in MCM700.
13
Genset
Training
GT_Session1.ppt
CW 170 Alternator Auxiliary Box (rear of alt box)
Alt Connection Box Photo
AVR Module
PT Fuse Protection
(3 x 2 amprated)
PT/CT Module
Voltage Regulator Output Module (A37)
The voltage regulator output module is a
power amplifier. This Board is used to amplify
the PWM signal from the PCC/PCS to drive
the exciter windings. Power from the PMG is
used by this board to amplify the PWM signal.
PT/CT Module (A36)
The PT/CT board converts generator output
voltage to approx 18VAC levels for the analogue
board. It also converts CT 0.55 amp (at full load)
output to approx 1.65 VAC ( at full load) input for
the analogue board.