DK Ba 0005 - GB, English

OPERATING INSTRUCTION
MMC 4000
V2.0
For Type Series 4000
DK-BA-0005 / V01 / 06.10.2009

Pos: 1 /Dokumentation/OX-Organisatorische Module/OX-Dokumentenanfang-0001 @ 4\mod_1237216782562_101.doc @ 107533 @ 1
©2009 MTU Onsite Energy GmbH
Original document was created in German.
This publication including all its parts is protected by copyright. Each instance of use requires the prior written
consent of MTU Onsite Energy GmbH. This applies in particular to duplication, dissemination, editing,
translation, microfilming and storage and/or processing in electronic systems, including databases and online
services.
Subject to technical alterations in the interest of further development.
2 DK-BA-0005 / V01 / 06.10.2009

Table of Contents
Table of Contents
Table of Contents ....................................................................................................................................................... 3
Update Listing DK-BA-0005....................................................................................................................................... 6
1 General .................................................................................................................................................... 7
1.1 System description “MMC”....................................................................................................................... 7
1.2 "MTU Engine Management" system description...................................................................................... 7
1.3 Safety instructions.................................................................................................................................... 7
1.4 Safety chain ............................................................................................................................................. 7
1.5 CPU.......................................................................................................................................................... 7
1.6 Selectivity of protective devices ............................................................................................................... 8
1.7 Shielded lines........................................................................................................................................... 8
1.8 Diagram documentation ........................................................................................................................... 8
1.9 Maintenance............................................................................................................................................. 8
1.10 Battery cutoff ............................................................................................................................................ 8
1.11 Critical malfunction messages ................................................................................................................. 9
2 Start/Stop procedure ........................................................................................................................... 10
2.1 Start sequence ....................................................................................................................................... 10
2.2 Stop sequence ....................................................................................................................................... 12
2.3 Emergency stop ..................................................................................................................................... 13
3 Operating conditions ........................................................................................................................... 14
3.1 Operation “manual mode” ...................................................................................................................... 14
3.2 Operation „automatic mode“ .................................................................................................................. 14
3.3 Grid standby operation........................................................................................................................... 14
3.3.1 Island operation via external instrumentation and control (not MCS) .................................................... 14
3.4 Grid switching-in..................................................................................................................................... 15
4 Potential-free contacts ........................................................................................................................ 16
5 Handling and visualisation.................................................................................................................. 17
5.1 Mode switch / feeler / emergency switch (switching system) ................................................................ 17
5.2 Display.................................................................................................................................................... 19
5.3 Parameter entry ..................................................................................................................................... 20
5.4 Description of the menu bar ................................................................................................................... 21
5.5 Login....................................................................................................................................................... 26
5.5.1 Login by entering a user name and password ....................................................................................... 26
5.5.2 Login by hardware USB dongle (optional) ............................................................................................. 26
5.6 Main menu.............................................................................................................................................. 27
5.7 System overview .................................................................................................................................... 28
5.8 Engine overview..................................................................................................................................... 29
DK-BA-0005 / V01 / 06.10.2009 3

Table of Contents
5.9 Electrical data .........................................................................................................................................30

5.9.1 Load step controller (optional)................................................................................................................31
5.9.2 Power factor (cosphi) controller (optional) .............................................................................................34
5.9.3 Generator data .......................................................................................................................................35
5.10 Water system..........................................................................................................................................36
5.11 Gas system.............................................................................................................................................38
5.11.1 Two-gas operation with two gas systems (optional) ..............................................................................38
5.11.2 Two-gas operation with only one gas system (optional) ........................................................................38
5.12 Additional function: Gas compressor (optional) .....................................................................................39
5.13 Gas leak test...........................................................................................................................................40
5.14 Oil system...............................................................................................................................................41
5.15 Alarms ....................................................................................................................................................43
5.16 Operating notifications............................................................................................................................45
5.17 Alarmlogger ............................................................................................................................................46
5.18 Output controller .....................................................................................................................................48
5.18.1 Origin of the setpoint ..............................................................................................................................48
5.18.2 Manual mode..........................................................................................................................................49
5.18.3 Automatic mode......................................................................................................................................49
5.18.4 Power reduced .......................................................................................................................................51
5.19 Start-/Stop procedure .............................................................................................................................52
5.20 Counter reading......................................................................................................................................54
5.21 Overview auxiliary features ....................................................................................................................56
5.22 Cleaning window ....................................................................................................................................57
5.23 Additional option: Water temperature controller (optional).....................................................................58
5.24 Additional option: Mixture water controller (optional) .............................................................................60
5.25 Additional option: Gas mix cooler and pump (optional)..........................................................................61
5.26 Additional function: Emergency cooling water controller (optional) .......................................................63
5.27 Additional function: Emergency cooler and pump (optional)..................................................................64
5.28 Additional function: Room temperature controller (optional)..................................................................67
5.29 Additional function: Room air fan ...........................................................................................................68
5.30 Additional function: Controller for CH4 (optional) ...................................................................................72
5.31 Additional function: Gas tank (optional) .................................................................................................74
5.32 Additional function: Grid feed-in control .................................................................................................77
5.33 Additional function: Exhaust-/ Butterfly valves (optional) .......................................................................82
5.34 Additional function: Engine heat operation (optional) ............................................................................83
5.35 Additional function: Boiler heat control (optional)...................................................................................89
5.36 Additional function: Outdoor temperature offset (optional) ....................................................................91
5.37 Additional function: Heating water reservoir (optional)...........................................................................93
5.38 Additional function: Timer (optional).......................................................................................................95
4 DK-BA-0005 / V01 / 06.10.2009

Table of Contents
5.39 Additional function: SMS / E-mail (optional)........................................................................................... 97

5.40 Service menu .......................................................................................................................................100
5.41 Additional function: External communication (optional) .......................................................................101
5.42 Interface protocol - general ..................................................................................................................104
5.43 M-Graph: Single channel .....................................................................................................................105
5.44 M-Graph: System diagram per second ................................................................................................106
5.45 M-Graph: System intraday ...................................................................................................................108
DK-BA-0005 / V01 / 06.10.2009 5

Update Listing DK-BA-0005
Pos: 2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Update Listing-0005 @ 6\mod_1250686770380_0.doc @ 185143 @ 1
Update Listing DK-BA-0005

Änderungen, Ergänzungen,
Ver-
Freigabenr. Datum Unterlagen im vorherigen Stand austauschen, Name
sion
nicht erwähnte Unterlagen bleiben gültig
Changes, additions
Ver-
Number Date Replace previous documents, documents not mentioned Name
sion
remain valid
Basisversion
07.09.06 Mörderisch
Basic Version
Anpassung auf MTU Baureihe 4000 (Phase 3)

Modification to MTU series 4000 (phase 3)
Anpassung der Cosphi-Regelung

Modification Cosphi-control
Update, Eingabe in Docuglobe

01 TM-174-BA 26.08.09 Alaca / Nörpel
Update, data entered into Docuglobe-System
6 DK-BA-0005 / V01 / 06.10.2009

General
Pos: 3.1 /Dokumentation/ÜB-Überschriften/1/ÜB-Allgemein @ 2\mod_1231765055200_101.doc @ 34881 @ 1
1 General
Pos: 3.2 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Systembeschreibung-MMC @ 2\mod_1233677379791_101.doc @ 51092 @ 2
1.1 System description “MMC”

Pos: 3.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Allgemein-001 @ 2\mod_1231773163680_101.doc @ 35073 @
 Industrial PC (IPC) with touch screen and various interfaces,

Windows XP Embedded operating system
 Computer-programmable control (CPC), programming in accordance with IEC 61131-3
 Various interfaces
 MTU synchronisation & protection (MSP)
 The module cabinet houses all monitoring and control mechanisms necessary for gas engine
operation. The system features various integrated closed-loop control systems (power, heating water,
etc.) and auxiliary drive controls.
Pos: 3.4 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-SystembeschreibungMotormanagement-001 @ 2\mod_1231776979526_101.doc @ 35128 @ 2
1.2 "MTU Engine Management" system description
 MTU Engine Management contains the monitoring and control systems required for gas engine
operation.
 Communication with the MMC takes place via CAN bus. Up-to-date engine data (analog values, status
messages) and alarm messages are communicated.
Pos: 3.5 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Sicherheitshinweise @ 2\mod_1233677375854_101.doc @ 51079 @ 2
1.3 Safety instructions

 The system may only be operated by authorised personnel employed by the operator. Maintenance
and switching work may only be carried out by external personnel with the operator's authorised
personnel present.
 It is essential to observe the regulations of the trade association when working on the switchgear.
 Only authorised personnel working with appropriate tools are permitted to replace fuse-elements.
 The manufacturer's maintenance instructions must be followed.
Pos: 3.7 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Sicherheitskette @ 2\mod_1233677371853_101.doc @ 51066 @ 2
1.4 Safety chain

The safety chain is equipped with 2 tested category 2 safety combinations.

 Machine safety chain (e.g. STL, centralised emergency off from CPC, etc.)
 Manual emergency off safety chain (e.g. emergency off at module cabinet, building emergency off,
etc.)
The corresponding drives (e.g. gas valves, etc.) are deactivated when one of the safety chains is triggered. A
manual emergency off deactivates all drives.
Pos: 3.9 /Dokumentation/ÜB-Überschriften/1.1/ÜB-CPU @ 2\mod_1233677538161_101.doc @ 51157 @ 2
1.5 CPU
The CPC's CPU is monitored by a watchdog. When this responds, all the CPC outputs are deactivated under
defined conditions and the safety chain is triggered. The CPU can only be reset by means of a cold restart (switch
miniature circuit-breaker off/on). Contact the Service department if the fault occurs again.
Pos: 3.11 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Selektivität-Schutzorgane @ 2\mod_1233677533817_101.doc @ 51144 @ 2
DK-BA-0005 / V01 / 06.10.2009 7

General
1.6 Selectivity of protective devices

The selectivity of the protective devices (fuses, circuit-breakers, etc.) is configured in the switchgear for the short-
circuit current in island operation or for operation in parallel with the grid. In island operation, however, only the
lesser short-circuit currents are available to the switched-in generators, and the selectivity of the protective devices
is restricted. The customer must ensure that the selectivity of the protective devices is guaranteed in the consumer
switchgear in this operating state.
Pos: 3.13 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Geschirmte-Kabel @ 2\mod_1233677529660_101.doc @ 51131 @ 2
1.7 Shielded lines

 The shield must be fitted very close to the connecting point.

 The shield must be fitted at one end (module cabinet).
 Insulation must be fitted at the non-fitted end of the shield.
Pos: 3.15 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Schaltplandokumentation @ 2\mod_1233677525519_101.doc @ 51118 @ 2
1.8 Diagram documentation

The wiring diagrams are specifically adapted for each system. The diagrams are created using the "WSCAD"
drawing system. Once the wiring diagrams have been drawn up, the following documents are available:
 Wiring diagrams
 Cable lists
 Parts lists
 Terminal diagrams
Pos: 3.17 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Wartung @ 2\mod_1233677521113_101.doc @ 51105 @ 2
1.9 Maintenance
Pos: 3.18 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Allgemein-010 @ 5\mod_1241515058211_101.doc @ 148683 @
The CP3485 central unit (CPC) is equipped with a battery. This battery must be replaced at regular intervals as
specified in the maintenance instructions.
The filter fan's filter mat also has to be cleaned when necessary.
Maintenance intervals:
 The battery for the central unit CP3485 (CPC) must be replaced every 4 years or when necessary.
 IPC battery replacement every 4 years
 The filter mat should be cleaned/replaced when necessary.
Pos: 3.19 /Dokumentation/ÜB-Überschriften/1.1ÜB-Batterieabschaltung @ 2\mod_1233677804600_101.doc @ 51222 @ 2
1.10 Battery cutoff

Pos: 3.20 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Batterieabschaltung-001 @ 2\mod_1231837122535_101.doc @ 35338 @
If the battery charger is unavailable for a prolonged period (> 5 hours) (in the event of a shutdown or a technical
fault affecting the charger, etc.), you should unscrew the screw-in fuse-link (35 A) for the battery system.
Otherwise, there is a risk of the controller batteries running completely flat.
 This slow discharge process under the permissible supply voltage for the control components can also
lead to data loss.
Pos: 3.21 /Dokumentation/ÜB-Überschriften/1.1ÜB-Kritische-Störmeldungen @ 2\mod_1233677801365_101.doc @ 51209 @ 2
8 DK-BA-0005 / V01 / 06.10.2009

General
1.11 Critical malfunction messages

 087 - Generator circuit-breaker will not open

If this alarm occurs, if possible, the system should not be stopped with a manual emergency off. The control
cannot open the circuit-breaker, so the engine would continue to rotate. However, the entire cooling and the
auxiliary drives shutting down would introduce a risk of damage beyond repair!
Remedy: Try to open the circuit-breaker by hand or try to open a higher-level switch.
 088 - Generator circuit-breaker will not open – trailing mode active

This alarm is a result of alarm message 87. Alarm message 87 was followed by a shutting-down alarm. The
system runs in trailing mode without fuel supply but with active auxiliary drives.
The same remedial measures as described for alarm message 87 apply.
Pos: 3.23 /OX-Seitenumbruch @ 0\mod_1218433559331_0.doc @ 255 @
DK-BA-0005 / V01 / 06.10.2009 9

Start/Stop procedure
Pos: 4.1 /Dokumentation/ÜB-Überschriften/1/ÜB-Start- / Stoppablauf @ 2\mod_1231512970323_101.doc @ 34803 @ 1
2 Start/Stop procedure
Pos: 4.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Startablauf-001 @ 2\mod_1233579752901_101.doc @ 48673 @ 2
2.1 Start sequence
 Start command (local/remote)

 Manual or automatic mode
 Genset ready for operation
Start precondition 1
 No grid failure (on systems which do not support island operation, MCB
is ON or option "no MCB")
 Automatic: All start conditions for automatic mode OK!
 No start command to MTU Engine Management
 Start command to MTU Engine Management

 Auxiliary drives and cooling water pump ON
Phase 1
 Open exhaust butterfly valves (optional)
 Start leak test (request from MTU Engine Management)
 Auxiliary drives ON
 Exhaust butterfly valve open (optional)
Start precondition 2  Leak test OK
 Message auxiliary drives ON + leak test OK to MTU Engine
Management
 Start abort phase 1 by MTU Engine Management
Phase 2  Open gas valves (request from MTU Engine Management)
 Gas valves are open (message gas valves open to MTU Engine
Management)
 Start abort phase 2 by MTU Engine Management
To phase 3
10 DK-BA-0005 / V01 / 06.10.2009

 Rated speed reached (message from MTU Engine Management)

Phase 3  Monitoring of generator voltage + generator frequency
 Activate run-on time for auxiliary drives
 Generator voltage > limit value

 Generator frequency > limit value
Start abort phase 3
 Enable synchronisation (message from MTU Engine Management)

 Enable speed control
Phase 4
 Automatic: Enable synchronisation + start time monitoring
 Manual: No synchronisation enable
Start precondition 5  Generator circuit-breaker is ON
Start abort phase 4
Operation in parallel with the grid: Monitoring of power regulation, ramp

Island operation: Activate island operation (frequency controller)
DK-BA-0005 / V01 / 06.10.2009 11

Pos: 4.4 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Stoppablauf-001 @ 2\mod_1233587176211_101.doc @ 48686 @ 2
2.2 Stop sequence
Phase 0  Genset in operation and stop pending
Stop precondition 0  Slow stop (ramp function)
 Quick stop (jump to phase 2 immediately)
Phase 1  Genset is relieved of load (ramp function)
Start condition 1
 Minimum power undershot or maximum time overshot
(delayed)
 Remains in phase 1
 Open generator circuit-breaker

 Activate speed control
Phase 2
 Activate run-on time for auxiliary drives
 Start command to MTU Engine Management
Module ready to start
12 DK-BA-0005 / V01 / 06.10.2009

Pos: 4.6 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-Startstoppablauf-003 @ 2\mod_1232540048659_101.doc @ 40748 @ 2
2.3 Emergency stop
Phase 1  Module in operation and emergency stop pending
Always deactivate without delay:

 Gas valves
 Ignition
 Speed controller
 Open generator circuit-breaker
 Start reclosing delay
In the case of machine emergency stop - deactivate function with

delay:
 Cooling water pump
 Exhaust butterfly valves
 Heating water pump
 Bypass butterfly valves
Phase 3
 Lube oil supply
 Ventilation
Exception: If one of these functions has triggered the emergency stop, it is
deactivated without delay.
In the case of manual emergency stop - deactivate function without

delay:
 Cooling water pump
 Exhaust butterfly valves
 Heating water pump
 Bypass butterfly valves
 Lube oil supply
 Ventilation
Pos: 5 /OX-Seitenumbruch @ 0\mod_1218433559331_0.doc @ 255 @
DK-BA-0005 / V01 / 06.10.2009 13

Operating conditions
Pos: 6.1 /Dokumentation/ÜB-Überschriften/1/ÜB-Betriebszustände @ 2\mod_1231836047462_101.doc @ 35288 @
3 Operating conditions
Pos: 6.2 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Betriebsart-Handbetrieb @ 2\mod_1233677797787_101.doc @ 51196 @ 2
3.1 Operation “manual mode”

Pos: 6.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Betriebszustände-001 @ 2\mod_1231836225585_101.doc @ 35300 @
In this operating mode, the module is started on a start request (all start conditions must be met) and runs up to idle
speed. The module then remains at idle speed (MMC400: maximum 2 hours; MMC4000: maximum 1 hour) until
synchronisation operation is initiated or a stop is activated.
In the case of synchronisation operation being initiated and completed successfully, a setpoint of approx. 10% is
assigned to the power controller. The power can now be adjusted manually.
Pos: 6.4 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Betriebsart-Automatikbetrieb @ 2\mod_1233677794474_101.doc @ 51183 @ 2
3.2 Operation „automatic mode“

Pos: 6.5 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Betriebszustände-002 @ 2\mod_1231853156750_101.doc @ 35413 @
In this operating mode the module starts following a start request and synchronizes with the grid automatically.
Dependent upon the selected mode of operation (fixed value control, variable value control, heat-controlled, etc.),
the current setpoint is transferred to the power controller (MMC400) or MTU engine management (MMC4000) and
approached.
 In automatic mode, various auxiliary features are integrated into the starting sequence. Dependent
upon which function is active (e.g. timer, grid feed-in control, CH4 content, etc.), the start enable for the
relevant feature is taken into account when a start request is active. In the event of a problem, a group
interrupt is output.
 If a drive or a controller (e.g. cooling water pump, etc.) is in manual mode when a start is initiated,
manual mode is reset. This ensures that no undefined switching states will occur in automatic mode
(e.g. the module would overheat if the cooling water pump was switched off).
Pos: 6.6 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Netzersatzbetrieb @ 2\mod_1233677790958_101.doc @ 51170 @ 2
3.3 Grid standby operation

Pos: 6.7 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Betriebszustände-004 @ 5\mod_1241525273987_101.doc @ 148819 @ 3
In isolated operation the power is determined by whichever consumers are switched in.
Speed control simply has to readjust the speed setpoint after load changes. This setpoint is specified via a
frequency controller.
On systems with multiple engines, gensets working in parallel must not be allowed to run with differing percentage
loads. An effective load distribution system is provided for this purpose. It compares the generator actual-power
output of the gensets which are switched in and sends actuating pulses to the speed controllers for the individual
gensets via the variable speed devices until the powers are balanced (proportional degree = 3 to 5%).
A frequency controller sends adjusting pulses simultaneously in the same direction to all variable speed devices in
order to balance the frequency deviations as quickly as possible.
The risk of signals travelling in opposite directions as a result of deviations in power and frequency is excluded by
an internal logic.
3.3.1 Island operation via external instrumentation and control (not MCS)
 See separate document, "Island operation via external instrumentation and control"
Pos: 6.8 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-BetriebsartNetzzuschaltung-001 @ 2\mod_1231855527665_101.doc @ 35481 @ 2
14 DK-BA-0005 / V01 / 06.10.2009

Operating conditions
3.4 Grid switching-in

Synchronous generators may only be connected to an existing network if their voltage, frequency and phase angle
are identical. To meet the required conditions, a synchroniser is required. The synchroniser uses the speed
controller to influence the frequency and speed of the generator up to the point of switching-in. The synchroniser is
deactivated following switching-in.
DK-BA-0005 / V01 / 06.10.2009 15

Potential-free contacts
Pos: 8.1 /Dokumentation/ÜB-Überschriften/1/ÜB-PotenzialfreieKontakte @ 3\mod_1234364354601_101.doc @ 60843 @ 1
4 Potential-free contacts
Pos: 8.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-PotenzialfreieKontake-001 @ 3\mod_1234364998225_101.doc @ 60855 @
The control outputs various floating contacts by default. These contacts can be used to activate a variety of drives
or to query the status of the system.
Specific projects may feature more of these messages.
Pos: 8.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-PotenzialfreieKontake-002 @ 3\mod_1234365091648_101.doc @ 60957 @
Readiness for operation:

This contact remains closed if the following criteria are met:
 Key-operated switched set to enable module
 Key-operated switch set to remote
 Key-operated switch set to automatic
 No stop or emergency stop pending
 Engine stationary and no start command pending
Pos: 8.4 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-PotenzialfreieKontakte-006 @ 5\mod_1241528892943_101.doc @ 148906 @
External auxiliary drives ON:

The contact is switched on during a start sequence. When the engine meets the operating conditions, the run-on
timer is activated. When the module is stopped again, the run-on timer for the auxiliary drives switches in. This
cools the engine. The contact is not switched off again until the run-on time has elapsed.
 The auxiliary drives are always switched off in the event of a "manual emergency off" (safety chain has
triggered).
 The auxiliary drives are also activated once for a run-on cycle if a PT1000 / PT100 temperature (e.g.
cooling water temperature, intake air temperature, etc.) has been exceeded. This is done with a view
to removing any heat which might have become trapped and returning the engine to readiness for
starting.
Module operation:
The contact is switched on as soon as the generator circuit-breaker closes.
"'Alarm" group message:

The contact opens if an alarm is pending. The machine continues to run.
Pos: 8.7 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-PotenzialfreieKontakte-004 @ 3\mod_1234365549716_101.doc @ 61133 @
"Stop" group message:

The contact opens if a stop or an emergency stop is pending. The machine stops and the readiness-for-operation
notification is no longer active. Only notifications activated accordingly in the alarm message parameters are
effective.
Engine running:
The contact is closed as soon as the engine reaches a speed in excess of 1000 rpm.
16 DK-BA-0005 / V01 / 06.10.2009

Handling and visualisation
Pos: 10.1 /Dokumentation/ÜB-Überschriften/1/ÜB-Bedienung-Visualisierung @ 2\mod_1231856037092_101.doc @ 35517 @ 1
5 Handling and visualisation

Pos: 10.2.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Wahlschalter-Taster-Notaus-Schaltanlage @ 2\mod_1233678197047_101.doc @ 51326 @ 2
5.1 Mode switch / feeler / emergency switch (switching system)

Pos: 10.2.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Schlüssel-001 @ 2\mod_1231856282226_101.doc @ 35541 @
Designation Type of switch Setting

Enable module Key-operated switch 0/1
This switch is used to suspend operation of the engine. If the machine is stationary, the module cannot start up.
If the machine is running, a controlled stop is induced.
0 = no enable, 1 = enable

Control local / remote Key-operated switch 0/1
This switch defines the operating location. For operation directly on the module, the switch must be set to
"Local", so that all setpoints can be modified on the IPC. The "Start/Stop switch" on the control cabinet is also
active. If the system is to be operated remotely (remote starting/stopping, remote setpoints, control via interface),
the switch must be set to "Remote".
0 = local operation, 1 = remote operation

Manual / Automatic Key-operated switch 0/1
In automatic mode, starting is initiated following a start command. The module is synchronised with the grid
automatically and the set power setpoint is approached (along a ramp). All control tasks are performed
automatically. In manual mode, starting is initiated following a start command. The module starts up and remains
ready for synchronisation once the rated speed is reached. In this phase the speed can be adjusted manually
(higher/lower pulses via buttons on the display). A further button (on the display) can be used to initiate
synchronisation. Once synchronisation with the grid is complete, the machine remains at the minimum setpoint
(approx. 10% power). The setpoint has to be adjusted by hand. All control tasks are performed automatically.
Precondition for manual mode: "Local control".
0 = manual mode; 1 = automatic mode

Start / Stop Key-operated switch 0/1
This switch can be used to initiate starting of the module locally. The "Local/remote control" key-operated switch
must be set to "Local".
DK-BA-0005 / V01 / 06.10.2009 17


Enable island operation Key-operated switch 0/1
Optional:
This switch can be used to enable automatic island operation. In this case, island operation is initiated
automatically in the event of a grid failure or grid circuit-breaker dropout (optional) in automatic mode. In manual
mode the circuit-breakers (GCB and MCB) can be operated by hand (open/close).
0 = no enable, 1 = enable

Power failure test Key-operated switch 0/1
Optional:
This switch is used to test a grid failure. When it is activated , a phase to the MSP (MTU synchronisation &
protection) is interrupted. A reaction is triggered in line with the setting of the "Enable island operation" switch.
In the case of enable, island operation is initiated; otherwise, the GCB is opened.
0 = no test, 1 = run test
Pos: 10.2.8 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-TasterReset-001 @ 2\mod_1231858085098_101.doc @ 35616 @

Reset Button
This button is used to acknowledge pending alarm messages. The safety relays drop out if an emergency stop is
pending. The safety relays and the corresponding alarm messages can only be activated and acknowledged via
this button. Only alarm messages for which no relays have to be activated can be acknowledged via the display
(R button).
Pos: 10.2.9 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Notausschalter-001 @ 2\mod_1231858218065_101.doc @ 35629 @

Emergency Off switch Emergency off
The "manual emergency off chain" is triggered without delay when the emergency off switch is activated. All
drives and the module are shut down immediately. The emergency stop chain cannot be reactivated until the
switch has been unlocked (the switch is unlocked using a key) and the reset button has been pressed.
18 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.4.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Display @ 2\mod_1233678190515_101.doc @ 51300 @ 2
5.2 Display
Pos: 10.4.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Display-001 @ 2\mod_1231858382066_101.doc @ 35761 @
All values read in by the module and the system can be displayed on the touch screen.
The display comprises various menus and is designed for touch operation. A keyboard and mouse are not required
for any of the operations. Entries can also be made via software keyboards. Various menus, parameters and
switches are only enabled for specific users (a grey background indicates that these are disabled).
To activate these, press the
button and log in. If the user is authorised, the menus and parameters are activated.
Pos: 10.4.3 /Dokumentation/Sicherheit/SH-Sicherheitshinweise/SH-Hinweis/SH-H-083 @ 4\mod_1237384887082_101.doc @ 110376 @
Note
A user needs to log in to perform operations and enter parameters.
DK-BA-0005 / V01 / 06.10.2009 19

Pos: 10.6.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Parameter-Eingabe @ 2\mod_1233678187109_101.doc @ 51287 @ 2
5.3 Parameter entry

Pos: 10.6.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Parametereingabe-001 @ 2\mod_1231861185744_101.doc @ 35787 @
All necessary parameters for the system can be modified via the display. Parameters are displayed in red text.
Click a parameter to open a data entry window.
Press "Enter" to confirm an entry.
The entry range is monitored for all parameters. If the entry is outside the entry range, the upper or lower limit is
applied automatically.
Pos: 10.6.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Parametereingabe-002 @ 4\mod_1238422898416_101.doc @ 123157 @
20 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.8.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Beschreibung der Menüleiste @ 2\mod_1233678183843_101.doc @ 51274 @ 2
5.4 Description of the menu bar

Pos: 10.8.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Menüleiste-001 @ 2\mod_1232372398558_101.doc @ 37804 @
Home button:
This button will always take you back to the initial screen.
You can keep pressing this button until you get to the "main menu".
Pos: 10.8.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Menüleiste-010 @ 5\mod_1241697999745_101.doc @ 149373 @
Help button:
Press the Help button to call up the version number of the current visualisation.
Note
Only possible from the main menu!
Pos: 10.8.5 /OX-Seitenumbruch @ 0\mod_1218433559331_0.doc @ 255 @
DK-BA-0005 / V01 / 06.10.2009 21

Switch language button:
You can switch the language with this button. Two languages (English, German) are supported by default. A
national language can be integrated as a third language option.
Pos: 10.8.7 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Menüleiste-011 @ 5\mod_1241699528774_101.doc @ 149403 @
Alarm messages button:
This button indicates that an alarm message is pending. Each of these buttons is linked to a group alarm message.
Press one of the buttons to switch to the alarm message window.
There are three different types of alarm message:

 Emergency stop (N):
System is shut down immediately, e.g. when the emergency off button is pressed.
 Stop (S):
System is stopped. This can take the form of a "controlled stop" or an "immediate stop".
Controlled stop: Module is relieved of its load along a power ramp.
Immediate stop: The power switch is opened without delay.
 Alarm (A):
An alarm has occurred which does not initiate a module shutdown.
The following states apply for all three buttons:

 No alarm pending:
The button is "blue".
 New alarm pending and not yet acknowledged:
The emergency stop (N) and stop (S) buttons are "red" and flashing.
The alarm button (A) is "yellow" and flashing.
 Alarm pending and has already been acknowledged:
If a group alarm is pending and the operator has already acknowledged it (by pressing the "Reset"
button), the emergency stop (N) and stop (S) buttons turn "red" and stop flashing
The alarm button (A) remains "yellow" and stops flashing.
22 DK-BA-0005 / V01 / 06.10.2009

Start request:
 If this button is red, no start request is pending at this time.

 If this button is green, a start request is currently pending (e.g. remote control and remote start
command).
Press this button to show a list of all start conditions for automatic mode. All functions activated in the system are
enabled and signalled. If the start condition is met (e.g. gas tank enables system) the LED for the gas tank turns
green (otherwise, it is red). This means that you can quickly tell which start condition remains to be met.
Note
Time of day and date button:
This button is used to set the time of day and date on the controller and the IPC. The project name is simply
displayed.
DK-BA-0005 / V01 / 06.10.2009 23

The time of day and the date for the controller and the IPC can be set on this page.
The time of day is important for time-stamping alarm messages. Data is entered in the red fields and then
transferred to the controller by pressing the "Set time" button.
If the transfer was successful, the current time of day (the set values) appears at the top and the seconds counter
is running.
In the event of an alarm the "Ack. alarm" button flashes. This button has to be pressed to acknowledge the alarm.
The operation can then be repeated.
Note
Note
The year cannot be set earlier than 2000.
24 DK-BA-0005 / V01 / 06.10.2009

Login button:
This button is used to enable various parameters and menu commands for the user. The parameters enabled for
each user are restricted. This prevents critical parameters being changed by unauthorised persons.
Note
DK-BA-0005 / V01 / 06.10.2009 25

Pos: 10.10.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Login @ 2\mod_1233678180218_101.doc @ 51261 @ 2
5.5 Login
Pos: 10.10.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Menüleiste-007 @ 2\mod_1233665456989_101.doc @ 49565 @ 3
This button is used to log in as a specific user. Various parameters and menus are enabled dependent upon which
user has logged in. Parameters can be modified here.
Users can only log in in the main menu. There are two different ways of logging in:
5.5.1 Login by entering a user name and password
For this login method users must enter a user name and a password as described below.
Default user and password:
You will receive this information separately from the operating instructions.
Sequence:
 Press the "Login" button.
 The login form opens.
Pos: 10.10.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Menüleiste-009 @ 4\mod_1238498407013_101.doc @ 123813 @ 3
 Enter the "User" and "Password" (complete the relevant fields).

 Select "Login" on the login form.
 The current user, the level and the logout time are displayed in the status bar.
 The window is closed automatically after a short period.
 The user is logged out automatically after a specific period of time.
 If an incorrect entry is made, the message "Wrong User or Password" appears in the status bar.
5.5.2 Login by hardware USB dongle (optional)
This login method does not require a user and password to be entered. Plug a USB dongle into the USB port on
the front of the IPC and press the "Login" button on the login form. The computer checks the dongle and then
activates the access level saved on the dongle. As long as the dongle remains plugged in, the user will not be
logged out automatically. If the dongle is removed, the user will be logged off within 10 minutes.
26 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.12.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Hauptmenü @ 2\mod_1233671170214_101.doc @ 49705 @ 2
5.6 Main menu

Pos: 10.12.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Hauptmenü-001 @ 2\mod_1233672111409_101.doc @ 50074 @
The main menu appears automatically when the PC starts up.

This screen is the uppermost level of the display.
The various lower-level screens can be selected with the menu buttons.
Pos: 10.12.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Hauptmenü-002 @ 5\mod_1241702993478_101.doc @ 149433 @
DK-BA-0005 / V01 / 06.10.2009 27

Pos: 10.14.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Anlagenuebersicht @ 2\mod_1233671243766_101.doc @ 49857 @ 2
5.7 System overview

Pos: 10.14.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Anlagenuebersicht-001 @ 2\mod_1233672407314_101.doc @ 50087 @
The system overview varies from project to project. System-specific data is displayed on this page.
Pos: 10.14.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Anlagenuebersicht-005 @ 5\mod_1242823784439_101.doc @ 156303 @
28 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.16.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Motoruebersicht @ 2\mod_1233671312067_101.doc @ 49870 @ 2
5.8 Engine overview

Pos: 10.16.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Motorübersicht-003 @ 6\mod_1249473252538_101.doc @ 181189 @
This screen shows an overview of all sensors and measured values associated with the engine as appropriate for
the particular type of engine.
Pos: 10.16.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Motoruebersicht-002 @ 5\mod_1242824491344_101.doc @ 156333 @
DK-BA-0005 / V01 / 06.10.2009 29

Pos: 10.18.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-ElektrischeDaten @ 2\mod_1233671417761_101.doc @ 49933 @ 2
5.9 Electrical data

Pos: 10.18.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-ElektrischeDaten-001 @ 2\mod_1233738239530_101.doc @ 52352 @
All important generator and system data appears on this screen.

The overview and data are determined by the selected options (e.g. with island operation).
Pos: 10.18.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-ElektrischeDaten-007 @ 5\mod_1242825085828_101.doc @ 156403 @
It is possible to operate the GCB manually from this screen (and the MCB as an option in the case of systems
which support island operation).
The following preconditions must be met:

 "Remote/Local" key-operated switch set to Local
 "Manual/Automatic" key-operated switch set to Manual
 Authorised user logged in
 The MCB can only be switched manually on a system which supports island operation!
 Precondition: The "Enable island operation" key-operated switch is set to "1"!
GCB:
If the MCB is closed, the "Close" button will not cause the circuit-breaker to cut in out of sync.
The circuit-breaker cannot be closed when the engine is at standstill.
MCB:
If the GCB is closed, the "Close" button will not cause the grid switch to cut in out of sync.
30 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.18.6 /Dokumentation/ÜB-Überschriften/1.1.1/ÜB-Laststufensteuerung @ 2\mod_1233741610793_101.doc @ 52713 @ 3
5.9.1 Load step controller (optional)

Load shedding control can be activated in island operation.

Up to 24 steps can be controlled. When island operation is initiated, the control issues the "Load shedding"
command.
Island operation does not continue and the GCB is not closed until a signal has been received indicating that load
shedding has been completed successfully ("Load shedding" LED).
As soon as the GCB signals that it is closed, the steps are switched back in at staggered intervals. The steps
continue to be switched in until the last step has been activated or an overload (optional evaluation) occurs.
Staggered switching-in of load steps enables the engine to optimise load regulation.
The number of load steps is defined in the general parameters.

 All load steps are switched back in at standstill or when the grid switch is closed.
 "Load shedding successful" checkback signal: All checkback signals for the individual steps are
connected in series.
 Steps for which a delay time of "0" has been entered are not shed (even in the event of an overload).
The load step contactors have to be controlled so that the contactors switch in when the coupling relay
drops out.
This ensures that power will continue to be supplied to the consumers even in the event of the control
system being affected by a failure or repair work.
DK-BA-0005 / V01 / 06.10.2009 31

With overload monitoring:

If the "Overload monitoring" option has been activated, power values can be assigned to the individual steps.
If the current module power actual value is > (power value (of the steps currently switched in) + overload limit
value), a time delay elapses.
At the end of this time an alarm message is output (overload in island operation) and a step is shed.
This procedure is repeated until the load returns to a value which undershoots the limit value or the last step which
can be shed has been shed. The steps are not switched back in until the alarm message has been acknowledged if
the load still exceeds the limit value.
If the extent of the load connected is so great that the module shuts down due to underfrequency, this monitoring
mechanism will not function.
Monitoring also ensures that the next step is not switched if the load to be expected exceeds the permissible load
for island operation (e.g. 90%). If it does, the alarm message is also output and the next step is not switched in.
32 DK-BA-0005 / V01 / 06.10.2009

Parameters for load step control:
The corresponding load step is not switched in until the time interval has
elapsed. The next interval then runs and a second step is switched in.
Special feature:
Steps with a delay time of 0 seconds are not shed. However, these
steps may only be defined at the start (e.g. step 1 and step 2).
As soon as a delay time has been defined for a step (e.g. step 3), a
delay time of 0 seconds cannot be entered for any subsequent step (e.g.
step 4).
Delay (1-24) s
Example for 4 load steps:
Correct:
Step 1 = 0 s, step 2 = 0 s, step 3 = 10 s, step 4 = 10 s
Incorrect:
Step 1 = 0 s, step 2 = 0 s, step 3 = 10 s, step 4 = 0 s
In the incorrect example, all delay times would then be set to the default
value of 2 seconds.
(This is done automatically by the system.)
Optional parameters for overload monitoring:
A maximum permissible power value is assigned to each step. The

power to be expected should not exceed this value. If the values entered
Power value %
exceed 100%, a default setting is applied (30/30/30). (This is done
automatically by the system.)
This value is added to the total power value (sum of all active steps). If
the current power actual value exceeds the limit value calculated in this
Overload limit %
way, once the overload delay has elapsed, an alarm message is sent
and the step is shed.
If the calculated overload limit is exceeded, this time interval elapses.

Overload delay s Once the interval has elapsed, the "Overload in island operation" alarm
message is output and the stages are shed as described above.
DK-BA-0005 / V01 / 06.10.2009 33

Pos: 10.18.14 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-ElektrischeDaten-011 @ 5\mod_1242826820502_101.doc @ 156543 @ 3
5.9.2 Power factor (cosphi) controller (optional)
The power factor can be adjusted variably by the MMC. To achieve this, the power factor controller at the generator
is controlled via a 4 - 20 mA signal. The setpoint and the corresponding control parameters can be set via the
display.
Parameters for power factor control:
The power factor controller is only enabled once the electrical power
Enable cosphi controller %
exceeds this limit value.
The required setpoint is set here. The setting limits are dependent
Setpoint
upon the generator.
Integral component of controller. The higher the value, the faster the
Ki
controller.
Integral time of the controller. The lower the value, the faster the
Tn s
controller.
The starting value can be set between 0% and 100% and influences
the 4-20 mA signal to the power factor controller.
0% means 4 mA, 100% means 20 mA.
The assignments between current and power factor are outlined in
Start %
the documentation for the RCI unit. The preset start value
determines the power factor for the inactive power factor controller
(power < enable limit value). When the controller is enabled, you
start with this value.
34 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.18.17 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-ElektrischeDaten-013 @ 5\mod_1244106986629_101.doc @ 163423 @ 3
5.9.3 Generator data
Press the "Generator" button to call up additional analog values for the generator.
DK-BA-0005 / V01 / 06.10.2009 35

Pos: 10.20.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Wassersystem @ 2\mod_1233671487828_101.doc @ 49946 @ 2
5.10 Water system

Pos: 10.20.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Wassersystem-001 @ 2\mod_1233743618025_101.doc @ 52843 @
All sensors and drives for the water system/hydraulic system appear on this screen.
It is divided into two sections: "heating water" and "cooling water". The various functions can be activated or
deactivated in the form of options.
The pumps can be operated by hand.
Pos: 10.20.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Wassersystem-006 @ 5\mod_1244108045154_101.doc @ 163533 @
You can also access the optional water temperature controller from this screen. To do this, activate the control
valve.
Parameters for the follow-up time of the auxiliary drives:
The auxiliary drives start up without delay

Follow-up time min during the starting procedure and run on for this
configurable time after shutdown.
Pos: 10.20.6 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Wassersystem-007 @ 5\mod_1244108847696_101.doc @ 163623 @
Preheating unit:
Module preheating makes it possible to keep the cooling water temperature within a configurable range.
 Internal preheating via built-on heating cartridges
Activating preheating also activates the cooling water pump.

Warm-up ramp (withstand value) - Optional:

This function increases the power ramp to a configurable value once the GCB has switched in. The ramp only
continues if the cooling water temperature has fallen below a limit value, which is also configurable.
36 DK-BA-0005 / V01 / 06.10.2009

Note
All functions are only active in automatic mode!
Parameters for warm-up ramp:
If the hold point for the setpoint ramp is activated, the

power setpoint will remain at this set value until the
Setpoint power % cooling water temperature IW reaches the set setpoint
SW. Only after this will the power setpoint continue to
increase.
The ramp does not continue until the set temperature has
Cooling water engine °C been reached.
DK-BA-0005 / V01 / 06.10.2009 37

Pos: 10.22.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Gassystem @ 0\mod_1218610328403_101.doc @ 634 @ 2
5.11 Gas system

Pos: 10.22.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Gassystem-007 @ 5\mod_1244115708677_101.doc @ 163813 @ 33
This screen provides an overview of the gas system.

The following types of gas system are possible:
 Single-gas operation
 Two-gas operation with two gas systems
 Two-gas operation with one gas system
All necessary parameters and data are displayed or can be adjusted.

It is possible to jump from this screen to the optional gas compressor and, at the appropriate level, the gas leak test
can be activated.
5.11.1 Two-gas operation with two gas systems (optional)
No enable!
5.11.2 Two-gas operation with only one gas system (optional)
No enable!
38 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.24.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Gasverdichter @ 2\mod_1233674163353_101.doc @ 50375 @ 2
5.12 Additional function: Gas compressor (optional)

Pos: 10.24.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Gasverdichter-001 @ 2\mod_1233819368636_101.doc @ 54775 @
The gas compressor is activated on a start request.

Once the ON delay (the time required to build up gas pressure) has elapsed, the subsequent starting of the engine
is enabled.
If the engine is stopped again, the gas compressor will continue to run for a configurable time (after "Close gas
valves").
Pos: 10.24.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Gasverdichter-003 @ 5\mod_1244120213904_101.doc @ 163983 @
Pos: 10.24.4 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Gasverdichter-004 @ 5\mod_1244120289840_101.doc @ 164009 @
Parameters for gas compressor:
Time which must elapse before operation continues with

Switch-on delay s
the subsequent starting of the engine.
The gas compressor runs on for this time (time starts
Switch-off delay s
when the gas valves close).
DK-BA-0005 / V01 / 06.10.2009 39

Pos: 10.26.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Gasdichtheitstest @ 2\mod_1233674364397_101.doc @ 50408 @ 2
5.13 Gas leak test

Pos: 10.26.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Gasdichtheitstest-002 @ 5\mod_1244120721962_101.doc @ 164063 @
Pos: 10.26.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Gasdichtheitstest-001 @ 2\mod_1233820204976_101.doc @ 54891 @
The gas leak test can be carried out manually when the machine is at standstill.
To do this, select the "Manual" button. The button turns orange.
You can now start the test with the "Enable" button.
All status messages can be monitored.
40 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.28.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Ölsystem @ 2\mod_1233674423323_101.doc @ 50431 @ 2
5.14 Oil system

Pos: 10.28.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Ölsystem-005 @ 5\mod_1244122720100_101.doc @ 164363 @
This screen provides an overview of the lube oil supply. It is divided into the following sections:
 Lube oil refill for the genset (standard)
 Control for used oil pump
 Control for fresh oil pump (optional)
Lube oil refill:

Automatic lube oil refilling is activated on request from MTU Engine Management.
To bridge the response time between the refill solenoid valve opening and oil level monitoring responding, the
solenoid valve is controlled as follows.
On request from MTU Engine Management the solenoid valve is opened for the opening time Tö.
It is then closed again for the pause time Tp.
After this the time Tö starts again.
This alternating cycle continues until the request is withdrawn by MTU Engine Management.
The number of requests from MTU Engine Management can be read off from the oil refill counter.
Parameters for lube oil refill:
Tö s Opening time for solenoid valve

Tp s Pause time for solenoid valve
DK-BA-0005 / V01 / 06.10.2009 41

Used oil pump:

The used oil pump can be operated via the control. Two control methods are supported:
 Local operation via display: Activate manual button
 Remote operation via key-operated switch on heat cabinet (optional)
Description of function:
The used oil pump can be selected on the display. The following buttons are available:
 Manual
 Start/Stop
Manual mode (press the "manual" button):

Press Start; pumping will continue until the optional "Used oil tank overfilling" or "Used oil tank level > max." contact
responds or the pump is switched off by hand.
Fresh oil pump (optional):

The fresh oil pump can be operated via the control.
Three control methods are supported:
 Automatic mode for lube oil refill
 Local operation via display: Activate manual button
 Remote operation via key-operated switch on heat cabinet (optional)
Description of function:
Automatic mode for lube oil refill:

The fresh oil pump is activated at the same interval as the solenoid valve.
The fresh oil pump can be selected on the display.
The following buttons are available:
 Manual
 Start/Stop
Manual mode (press the "manual" button):

Press Start, pumping will continue until the "Level < min." contact for refilling is no longer active. Pulse filling will
then be activated until the "Level > max." contact on the engine oil pan or the optional "Fresh oil tank fill level < min.
2" contact responds. The pump can also be switched off by hand.
42 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.30.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Störmeldungen @ 2\mod_1233674518766_101.doc @ 50444 @ 2
5.15 Alarms
Pos: 10.30.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Störmeldungen-001 @ 2\mod_1233828358532_101.doc @ 55831 @
This screen provides an overview of all pending alarm messages.

It is also possible to switch to the alarm logger from here. The logger records all alarms and status messages over
a prolonged period with time-stamping.
This enables faults to be analysed more effectively.
Pos: 10.30.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Störmeldungen-003 @ 5\mod_1244554011621_101.doc @ 165793 @
Pos: 10.30.4 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Störmeldungen-004 @ 5\mod_1244554399022_101.doc @ 165823 @
How it works:
The window opens automatically whenever a new alarm message is pending.
In the event of a new alarm message, the corresponding group message flashes in the menu bar (e.g. N flashes
red: a new emergency stop is pending). The alarm messages can be acknowledged with the Reset button.
If the alarm message is no longer pending, the text disappears.
 Shutting-down alarm messages are displayed in red.
 Non-shutting-down alarm messages are displayed in yellow.
Acknowledged alarm messages are displayed in the "Ack" column.
Press the Home button to exit the alarm messages window.
The alarm messages window will only appear again when a new alarm message occurs or if selected via the N, S
or A button.
 The alarm messages are saved in a list.
Some system-specific messages can also appear in the list.
The list is always created on a project-specific basis.
Two important distinctions need to be made with regard to alarms for the alarm messages overview:
1) Self-acknowledging alarms: These alarms are reset automatically and deleted from the alarm messages
overview when their cause is rectified.
2) Non-self-acknowledging alarms: These alarms can only be reset by the user by pressing the Reset button (on
the control cabinet or on the alarm messages screen) once their cause has been rectified.
DK-BA-0005 / V01 / 06.10.2009 43

 Alarm messages which trigger the emergency stop chain can only be acknowledged by means of a
hardware reset (button on the MMC control cabinet).
The "Source" column is only of interest for multi-module systems and the central fault history, as the module
number is indicated here in order to identify which module is affected by the fault.
If the number of alarms is so great that not all of them can be displayed in the table, you can use the up and down
arrow buttons on the right-hand side of the table to scroll through its content.
 Alarms which have already been rectified can also be viewed with the alarm logger.
44 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.32.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Betriebsmeldungen @ 2\mod_1233830970194_101.doc @ 55921 @ 2
5.16 Operating notifications

Pos: 10.32.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Betriebsmeldungen-001 @ 2\mod_1233830841170_101.doc @ 55909 @
This screen provides an overview of all pending status messages (cooling water pump is ON, generator circuit-
breaker is OFF, etc.).
It is laid out in the same way as the alarm messages screen. Every active status message is displayed in green.
The alarm logger can also be called up here.
DK-BA-0005 / V01 / 06.10.2009 45

Pos: 10.34.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Alarmlogger @ 2\mod_1233674570207_101.doc @ 50467 @ 2
5.17 Alarmlogger
Pos: 10.34.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Alarmlogger-003 @ 5\mod_1244556136611_101.doc @ 165903 @
Pos: 10.34.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Alarmlogger-001 @ 2\mod_1233834720684_101.doc @ 55955 @
Use the alarm logger button in the alarm messages or status messages window to switch to the window displaying
the fault history.
When you switch to the alarm logger screen, the system runs through the fault database and displays a list of the
alarms which have been logged and rectified in the last 24 hours.
Once an alarm has been rectified, the suffix "gegangen!" ("gone!") is added to the corresponding alarm message
and displayed alongside it.
The "Source" column is only of interest for multi-module systems and the central fault history, as the module
number is indicated here in order to identify which module was affected by the fault.
If the number of alarms is so great that not all of them can be displayed in the table, you can use the up and down
arrow buttons on the right-hand side of the table to scroll through its content.
Start! button:
Use the Start! button to start a new search run.
Filter! button:
The Filter! button opens a selection window where criteria for the search run in the database can be set.
Pos: 10.34.4 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Alarmlogger-004 @ 5\mod_1244556361943_101.doc @ 165933 @
46 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.34.5 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Alarmlogger-002 @ 2\mod_1233834928884_101.doc @ 55979 @
There are four filter criteria. A green border indicates that a filter criterion is active.
Message type:
Here you can select whether you wish the list to contain only alarm messages (AM), only status messages (SM) or
both types of message (AM + SM). The default setting is alarm message (AM).
Kind:
Here you can select whether you wish to display the incoming state of an alarm, the outgoing state of an alarm or
both. The default setting is both.
Alarm number:
If you are just looking for the occurrence of a specific message, you can also activate a search based on a
message number via the "Nb.-Search" button. You also have to enter the number you are looking for in the field
underneath the button. Up to 4 numbers can be selected. The numbers can be reset with the "Default" button.
Days:
By default the database is always searched for events from the previous day. In the first field you can specify that
the database should also be searched for older events. The maximum value is 31 days.
The value of the second field must always be set to 1. To search for events within a certain time range, e.g. in the
previous 10 and 20 days, you will need to modify the value in the second field also. The value of the second field
must always be greater than that of the first field, although the maximum value of "31" still applies.
Save! button:
Use this button to copy the current database to directory "D:\MTU\FileSharing", which is enabled for customer
access.
Press the Home button to exit the alarm logger window.
DK-BA-0005 / V01 / 06.10.2009 47

Pos: 10.36.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Leistungsregler @ 2\mod_1233674683136_101.doc @ 50480 @ 2
5.18 Output controller

Pos: 10.36.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Leistungsregler-001 @ 3\mod_1233929326324_101.doc @ 56709 @
This screen provides a comprehensive overview of power regulation.

All the significant states and online data associated with the power controller appear on the right-hand side of the
screen.
Pos: 10.36.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Leistungsregler-006 @ 5\mod_1244557271061_101.doc @ 165986 @
Pos: 10.36.4 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Leistungsregler-002 @ 3\mod_1233931070086_101.doc @ 56853 @ 3
5.18.1 Origin of the setpoint
The selected operating state is displayed at the top of the screen.

 Local
 Remote
 Interface
 Timer
 Manual
The corresponding LED is lit and the valid operating mode (setpoint origin) appears against a green background
(e.g. moving value).
48 DK-BA-0005 / V01 / 06.10.2009

5.18.2 Manual mode
The power setpoint can also be set by hand.

To do this, set the key-operated switch to "Manual" and the operating mode to "Local".
When the key-operated switch is changed over, the "Manual" button turns orange.
You can now enter a "manual value" and apply this by pressing the OK button.
To exit manual mode, turn the key-operated switch back to "Automatic". The currently valid setpoint is reapplied.
Parameters for manual mode:
The value for manual mode applied by pressing the OK

Manual %
button.
5.18.3 Automatic mode
 1 = Module OFF
 2 = Moving value
 3 = Fixed value 1
 4 = Fixed value 2
 5 = Grid feed-in contr
 6 = Gas tank
 7 = Controller for CH4
 8 = Current operation - fixed at 100%
 9 = Heat operation
 10 = Heat operation (floating)
 11 = Heat operation (feed-in limit)
 12 = Heating water reservoir - fixed at 100%
Local changeover:
The key-operated switch must be set to "Local". Press the corresponding button (e.g. Moving value 1) to change
the operating mode over.
Remote changeover (hardware):
Up to four digital inputs are available for this purpose; when combined correctly, they can be used to activate all
operating modes (binary coding). Interface operation must not be active!
Changeover via interface:
The interface must be active and the corresponding data point must contain the required number.
Changeover via timer:
The changeover is time-controlled (see the description of the timer).
DK-BA-0005 / V01 / 06.10.2009 49

Pos: 10.36.9 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Leistungsregler-005 @ 3\mod_1233931826571_101.doc @ 56899 @
Valid setpoint:
Moving value:
Two values are displayed:
 Local: This value is valid if the "Control" key-operated switch is set to "Local".
The setpoint can be entered directly.
 Remote: This value is valid if the "Control" key-operated switch is set to "Remote".
The setpoint is specified via a 4-20 mA signal. If control is via the interface, the value is specified in the
telegram.
Fixed value 1 (optional):

 Local: This value is valid if the "Control" key-operated switch is set to "Local". The setpoint can be
entered directly.
 Remote: This value is valid if the "Control" key-operated switch is set to "Remote". A digital input
signal is used to request the value (corresponds to the local value).
If control is via the interface, the value is specified in the telegram.
Fixed value 2 (optional):

 Local: This value is valid if the "Control" key-operated switch is set to "Local". The setpoint can be
entered directly.
 Remote: This value is valid if the "Control" key-operated switch is set to "Remote". A digital input
signal is used to request the value (corresponds to the local value).
If control is via the interface, the value is specified in the telegram.
Grid feed-in control (optional):

When this operating mode is active, the current setpoint is taken from grid feed-in control.
(See auxiliary features.)
Gas tank (optional):
When this operating mode is active, the current setpoint is taken from gas tank control.
Controller for CH4 (optional):
When this operating mode is active, the current setpoint is taken from CH4 control.
Current operation (optional):
When this operating mode is active, the setpoint is set to 100%.
Heat operation (optional):
When this operating mode is active, the current setpoint is taken from heat control.
Heat operation - floating (optional):
50 DK-BA-0005 / V01 / 06.10.2009

Heat operation (grid feed-in limit) (optional):

Heating water reservoir (optional):
When this operating mode is active, the setpoint is set to 100%.
Pos: 10.36.10 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Leistungsregler-007 @ 5\mod_1244625506421_101.doc @ 166413 @ 3
5.18.4 Power reduced
This section of the screen shows whether or not power reduction is active. Power reduction can be triggered by a
variety of factors:
 Knocking
Power reduction due to knocking is applied by MTU Engine Management. A corresponding reduction is indicated.
 Gas change (optional):
The power is reduced to a configurable value whilst the gas is being changed. This value can even undershoot the
module's minimum load.
DK-BA-0005 / V01 / 06.10.2009 51

Pos: 10.38.1 /Dokumentation/ÜB-Überschriften/1ÜB-Startstoppablauf @ 2\mod_1233675028283_101.doc @ 50579 @ 2
5.19 Start-/Stop procedure

Pos: 10.38.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Startstoppablauf-007 @ 5\mod_1244638269894_101.doc @ 166720 @
Pos: 10.38.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Startstoppablauf-001 @ 3\mod_1233934881685_101.doc @ 57067 @
Start and stop sequences can be monitored on this screen. When the module starts up, the individual start phases
become active. Speed, synchronisation and power can be controlled manually.
Pos: 10.38.4 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Startstoppablauf-008 @ 5\mod_1244638701116_101.doc @ 166753 @
Manual mode:
 Key-operated switch set to local
 Key-operated switch set to manual
 Activate start request locally (key-operated switch)
 The engine starts up and remains in phase 3 (no synchronisation initiated).
 The speed can now be adjusted at idle speed with the up/down buttons.
 To initiate synchronisation, press the "Synchronisation" button. MTU Engine Management must also
send a synchronisation enable (digital input signal), see "Enable synchronisation" display.
 If the generator circuit-breaker is closed, 10% is activated automatically. The power can now be
specified. There are two ways of altering the power:
- Using the up/down buttons and the corresponding touch value
- Using a configurable manual setpoint and the OK button
52 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.38.6 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Startstoppablauf-002 @ 3\mod_1233935249072_101.doc @ 57091 @
Parameters for manual mode:
Typed value
(entered between the The setpoint is modified by this value every time the
%
"Up" and "Down" Up/Down buttons are pressed.
buttons)
Manual value
This is the value for manual mode applied by pressing the
(to the left of the"OK" %
OK button.
button)
DK-BA-0005 / V01 / 06.10.2009 53

5.20 Counter reading

Pos: 10.40.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zählerstand @ 6\mod_1245846051859_101.doc @ 170969 @ 2
Pos: 10.40.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Zählerstand-001 @ 6\mod_1245846244525_101.doc @ 171025 @
Some of the counter readings are optional (gas quantity, current counter, heat quantity, steam, reserve).
These counters are evaluated based on a pulse signal, whereby the pulse value is added on every pulse. This is
specified in the module parameters.
Note
Counter reading settings:
A desired counter reading value can be entered in the "Setpoint" field. Pressing the "Reset" button
for a counter applies this value as the current counter reading for this counter.
This is only enabled at a higher user level.
54 DK-BA-0005 / V01 / 06.10.2009

Pressing the "Save" button opens the following screen:
A back-up of the last 365 days can be saved here, with the most important operating values being date-stamped.
DK-BA-0005 / V01 / 06.10.2009 55

Pos: 10.42.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-ÜbersichtZusatzfunktionen @ 2\mod_1233675107148_101.doc @ 50602 @ 2
5.21 Overview auxiliary features

Pos: 10.42.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Zusatzfunktionen-002 @ 5\mod_1244639580757_101.doc @ 166806 @
Pos: 10.42.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-ÜbersichtZusatzfunktionen-001 @ 3\mod_1233935905231_101.doc @ 57115 @
The individual sub-functions can be called up via the corresponding buttons (as in the main menu).
Functions which are not enabled are greyed out and therefore cannot be selected.
56 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.44.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Reinigungsfenster @ 2\mod_1233675168449_101.doc @ 50615 @ 2
5.22 Cleaning window

Pos: 10.44.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Reinigungsfenster-002 @ 5\mod_1244639879861_101.doc @ 166859 @
Pos: 10.44.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Reinigungsfenster-001 @ 3\mod_1233936248361_101.doc @ 57139 @
It is easy to clean the monitor when this screen is displayed, as it does not feature any controls. Only one element
(the Home button) affects the appearance of the screen.
DK-BA-0005 / V01 / 06.10.2009 57

Pos: 10.46.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Wassertemperaturregler @ 2\mod_1233675230390_101.doc @ 50638 @ 2
5.23 Additional option: Water temperature controller (optional)

Pos: 10.46.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Wassertemperaturregler-004 @ 5\mod_1244640613980_101.doc @ 166920 @
Pos: 10.46.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Wassertemperaturregler-001 @ 3\mod_1233936877774_101.doc @ 57163 @
The controller takes the form of a PI controller, whose output variable can set the control valve from completely
closed (0%) to completely open (100%).
Control response:
Actual value < Setpoint: The control valve closes (no further than the minimum opening setting).
Direction:
If the mechanics of the control valve are not compatible with this direction, a module parameter can be used to
rotate the manual variable.
Two types of actuator can be used for the temperature controller:
 Analog actuator (standard: 0 to 10 V)
 Actuator with open/close pulses (with end positions)
Manual mode can be initiated for both actuators.

Manual mode is reset every time the module restarts.
Special feature:
Actuator with open/close pulses and end positions:
 Every time the follow-up time elapses, a reference run is performed.
This enables the running time of the valve to be determined and the pulse/delay duration provides a
means of calculating the position of the control valve at all times.
The reference run can also be activated manually at standstill via the "Reference Matching Active"
button.
Once a reference run has been started it cannot be aborted.
58 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.46.5 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Wassertemperaturregler-005 @ 5\mod_1244640743913_101.doc @ 166946 @
Parameters for temperature controller:
This parameter corresponds to the setpoint for the

Setpoint °C controller. On completion of the start ramp the controller
sets the temperature to this value.
Start setpoint °C The start ramp (for the temperature) starts at this value.
This is the time during which the start ramp is increased
Warm-up time min
from the start setpoint to the actual setpoint.
When control is deactivated, the controller still has a
Follow-up time min
configurable follow-up time.
Proportional component of controller. For every °C
deviation the manual variable is opened or closed by this
factor (e.g. system deviation +5 °C, KP=6: proportional
KP component of manual variable is 30%).
The KP can be set separately for normal operation and for
the warm-up time.
Integral component of controller. If the system deviation
persists, every time the follow-up time (Tn) expires, the Ki
Ki value is added to the P component and output. A high Ki
value may result in oscillation of the manual variable for
the control valve.
The follow-up time is used to calculate the I component.
The output value of the I controller is then added to the
output value of the P controller at these intervals. A follow-
Tn s up time which is too low may result in oscillation of the
manual variable for the control valve.
The Tn can be set separately for normal operation and for
the warm-up time.
During operation the valve is only closed or opened as far
Minimum opening % as this opening angle (dependent upon the direction of
action which can be entered here).
If manual mode is activate, this setpoint is output to the
Manual setpoint %
control valve.
Additional parameters for three-step controller:
A pulse (open or close) is output for the set time. The

same delay time elapses after every pulse.
Example: If you have a valve with a running time of 130
Pulse time ms seconds (from open to closed) and set a time of 1300 ms,
the manual variable would change by 1% per pulse. For a
control valve with end positions, the running time is
calculated through the reference run.
DK-BA-0005 / V01 / 06.10.2009 59

Pos: 10.48.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Gemischwasser-Regler @ 2\mod_1233675378837_101.doc @ 50651 @ 2
5.24 Additional option: Mixture water controller (optional)

Pos: 10.48.2 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-Gemischwasserregler-001 @ 3\mod_1234168102880_101.doc @ 57293 @
This function controls the engine's mixture water to a defined setpoint.

Control response:
Actual value < Setpoint: The control valve closes (no further than the minimum opening setting).
This controller works in the same way as the water temperature controller.
60 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.50.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-GemischlüfterPumpe @ 2\mod_1233675460842_101.doc @ 50664 @ 2
5.25 Additional option: Gas mix cooler and pump (optional)

Pos: 10.50.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-GemischlüfterPumpe-001 @ 3\mod_1234168316878_101.doc @ 57305 @
This function cools the gas mix (after cooler).

Pos: 10.50.3 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-GemischlüfterPumpe-005 @ 5\mod_1245237056197_101.doc @ 167343 @
The number of available stages is determined by way of a module parameter.

A maximum of 6 stages are available. One stage represents just one switching point. This can also mean that a fan
with a star/delta connection is set up with two stages.
For manual mode, it is possible to switch between the individual stages with the arrow keys.
If a stage is in operation, this is indicated by a green LED. It is also possible to operate each stage manually.
Manual mode is also signalled by an orange LED lighting up.
The function of each individual stage can be defined using the following four parameters:
Parameters for after cooler stages:
If the temperature actual value exceeds this limit value,

Value to switch on °C
the cooler stage is activated after the ON delay elapses.
Switch-on delay s ON delay for the cooler stage
If the temperature actual value drops below this limit
Value to switch off °C value, the cooler stage is deactivated after the OFF delay
elapses.
Switch-off delay s OFF delay for the cooler stage
DK-BA-0005 / V01 / 06.10.2009 61

Lube oil pump:

The mixture pump is activated at rated speed. The pump can also be operated by hand at standstill.
Variant 2: Fans via frequency converter:
With this variant the after cooler fans are controlled using a frequency converter. A PI controller is used for this
purpose. It outputs the setpoint (0-10 V) to the frequency converter. The setpoint can also be set by hand.
Parameters for frequency converter:
The PI controller's control parameters are identical to those of the water temperature controller. However, there are
no warm-up and follow-up times.
Lube oil pump:

The mixture pump is activated at rated speed. The pump can also be operated by hand at standstill.
62 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.52.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-NotkühlwasserRegler @ 2\mod_1233675612399_101.doc @ 50677 @ 2
5.26 Additional function: Emergency cooling water controller (optional)

Pos: 10.52.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-NotkühlwasserRegler-001 @ 3\mod_1234173942350_101.doc @ 57744 @
This function controls the engine's cooling circuit to a defined setpoint.

Control response:
Actual value > Setpoint: Control valve opens
 This controller works in the same way as the water temperature controller.
DK-BA-0005 / V01 / 06.10.2009 63

Pos: 10.54.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-NotkühlerlüfterPumpe @ 3\mod_1234176041395_101.doc @ 57922 @ 2
5.27 Additional function: Emergency cooler and pump (optional)

Pos: 10.54.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-NotkühlerlüfterPumpe-007 @ 5\mod_1245238471770_101.doc @ 167483 @
Variant 1: Emergency cooler fans via stage switching (speed control):
Pos: 10.54.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-NotkühlerlüfterPumpe-001 @ 3\mod_1234174369226_101.doc @ 57778 @

A maximum of 8 stages are available. One stage represents just one switching point. This can also mean that a fan
with a star/delta connection is set up with two stages.
For manual mode, it is possible to switch between the individual stages with the arrow keys. The current
parameters are displayed for the selected stage (No.).
If a stage is in operation, this is indicated by a green LED.
It is also possible to operate each stage manually. Manual mode is also signalled by an orange LED lighting up.
The function of each individual stage can be defined using the following four parameters:
Parameters for emergency cooler stages:

Value to switch on °C the emergency cooler stage is activated after the ON
delay elapses.
Switch-on delay s ON delay for the emergency cooler stage
Value to switch off °C value, the emergency cooler stage is deactivated after the
OFF delay elapses.
Switch-off delay s OFF delay for the emergency cooler stage
64 DK-BA-0005 / V01 / 06.10.2009

Emergency cooler pump:

Like the fan stages, the emergency cooler pump can also be configured with a parameter set.
It is also possible to operate the pump manually.
Parameters for emergency cooler pump:

Value to switch on °C
the pump is activated after the ON delay elapses.
Switch-on delay s ON delay for the pump
Value to switch off °C value, the pump is deactivated after the OFF delay
elapses.
Switch-off delay s OFF delay for the pump
Variant 2: Emergency cooler fans via frequency converter:
With this variant the emergency cooler fans are controlled using a frequency converter.
Up to 2 frequency converters can be used.
A PI controller is used for this purpose. It outputs the setpoint (0-10 V) to the frequency converter.
The setpoint can also be set by hand.
However, there is only one setpoint if 2 frequency converters are used!
DK-BA-0005 / V01 / 06.10.2009 65


Setpoint °C
controller.
The frequency converter is enabled when the limit value is
reached.
System-specific:
e.g. activation via the setting of an emergency cooler
Value to switch on % or °C
control valve (%) or based on water temperature (°C).
If you are using 2 frequency converters the second
FC is enabled using the manual variable of the first
FC!
If the limit value is undershot the frequency converter
Value to switch off °C
shuts down.
When the frequency converter is deactivated, this value is
transferred to the emergency cooler control valve as the
setpoint. This is in an attempt to achieve bumpless
Transfer value % changeover.
If you are using 2 frequency converters this value is
assigned to the first FC as the manual variable!
deviation the manual variable is increased or decreased
KP
by this factor (e.g. system deviation +5 °C, KP=6:
proportional component of manual variable is 30%).
the frequency converter.
Tn s output value of the P controller at these intervals. A follow-
up time which is too low may result in oscillation of the
manual variable for the frequency converter.
Manual variable %
frequency converter.
66 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.56.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-RaumtemperaturRegler @ 2\mod_1233675729125_101.doc @ 50690 @ 2
5.28 Additional function: Room temperature controller (optional)

Pos: 10.56.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-RaumtemperaturRegler-001 @ 3\mod_1234179242683_101.doc @ 57934 @
This function controls the room temperature to a defined setpoint.

Butterfly valve control (intake air, exhaust air, circulating air) must be set via the hardware so that one actuating
signal (e.g. 0 to 10 V) will set all butterfly valves to the correct position.
Control response:
Actual value > Setpoint: Control valve opens
 This controller works in the same way as the water temperature controller.
DK-BA-0005 / V01 / 06.10.2009 67

Pos: 10.58.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Raumlüftersteuerung (optional) @ 6\mod_1246007204449_101.doc @ 172473 @ 2
5.29 Additional function: Room air fan

Pos: 10.58.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Raumlüftersteuerung-007 @ 5\mod_1245240160653_101.doc @ 167619 @
Variant 1: Room air fans via stage switching (speed control):
Pos: 10.58.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Raumlüftersteuerung-001 @ 3\mod_1234179712000_101.doc @ 57958 @

Up to 4 stages are available (intake air and exhaust air). One stage represents just one switching point.
This can also mean that a fan with a star/delta connection is set up with two stages.
For manual mode, it is possible to switch between the individual stages with the arrow keys. The current
parameters are displayed for the selected stage (No.).
When one stage is in operation, this is signalled by a green LED. It is also possible to operate each stage manually.
Manual mode is also signalled by an orange LED lighting up.
The function of each individual stage can be defined using the following four parameters.
Parameters for room air fan stages:

Value to switch on °C the room air fan stage is activated after the ON delay
elapses.
Switch-on delay s ON delay for the room air fan stage.
Value to switch off °C value, the room air fan stage is deactivated after the OFF
delay elapses.
Switch-off delay s OFF delay for the room air fan stage.
 Optional: In the event of a gas pre-alarm, all fan stages are forcibly activated. In the event of a gas
main alarm, the fans are forcibly shut down.
68 DK-BA-0005 / V01 / 06.10.2009

Activating the room air fans (freely settable):

The fan enable can be set as required via the "Room air fans enable" button.
The following combinations are possible:

Enable even if the system is at standstill:
The fans are even switched on when the machine is stationary if the limit value is exceeded.
Enable only if the system is in operation:
The fans are only enabled if the machine is running and the limit value is exceeded.
Stage 1 immediately during operation:
This option can be selected in addition to the two variants listed above.
The first fan stage is then enabled immediately when the engine starts up (regardless of the limit value).
DK-BA-0005 / V01 / 06.10.2009 69

Variant 2: Room air fans via frequency converter

With this variant the room air fans (intake air/exhaust air) are controlled using a frequency converter.
A PI controller is used for this purpose. It outputs the setpoint (0-10 V) to the frequency converter.
The setpoint can also be set by hand.
70 DK-BA-0005 / V01 / 06.10.2009


Setpoint °C
controller.
If the machine is stationary, this value is added to the
setpoint. This prevents continuous switching on and off at
Offset standstill °C
standstill and also removes any heat which might have
become trapped.
This value is added to the setpoint. If the room
Value to switch on °C temperature exceeds the total value, the frequency
converter is enabled.
This value is subtracted from the setpoint. If the room
Value to switch off °C temperature is lower than the total value, the frequency
converter is switched back off.
deviation the manual variable is increased or decreased
KP
by this factor (e.g. system deviation +5 °C, KP=6:
proportional component of manual variable is 30%).
the frequency converter.
Tn s output value of the P controller at these intervals. A follow-
up time which is too low may result in oscillation of the
manual variable for the frequency converter.
During operation the manual variable is not output less
Minimum opening %
than this value.
Manual setpoint %
frequency converter.
DK-BA-0005 / V01 / 06.10.2009 71

Pos: 10.60.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-CH4-Regelung (optional) @ 6\mod_1246007287417_101.doc @ 172499 @ 2
5.30 Additional function: Controller for CH4 (optional)

Pos: 10.60.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-CH4Regelung-009 @ 6\mod_1245242761196_101.doc @ 167782 @
CH4 control is divided into several areas:

 Start enable for the engine based on the CH4 content
(digital contact or limit value via analog actual value signal)
 Power limitation based on the CH4 content
(subject to an analog actual value signal being available)
Note
Start enable via digital contact:

The module is enabled or shut down based on the CH4 content. A digital transmitter is read in for this purpose. The
following parameters are made available:
If the contact is pending, this time will elapse. The module

Switch-on delay s is not enabled until this time has elapsed and the signal is
pending.
If the contact is no longer pending, this time will elapse.
Switch-off delay s The module is disabled once this time has elapsed and
the signal is pending.
72 DK-BA-0005 / V01 / 06.10.2009

Start enable via analog signal - optional:

The module is enabled or shut down based on the CH4 content. An analog actual value signal is read in and
compared with the limit values.
The following parameters are made available:
If the actual value exceeds this limit, the ON timer will

At CH4 content on %
elapse.
If the limit value is exceeded, this time elapses.
Switch-on delay s The module is not enabled until this time has elapsed and
the limit value is exceeded.
If the actual value exceeds this limit, the OFF timer will
At CH4 content off %
elapse.
If the limit value is undershot, this time elapses.
Switch-off delay s The module is not disabled until this time has elapsed and
the limit value is undershot.
 The characteristic must be plotted by the customer.

Power limitation via analog signal - optional:

The power of the engine is limited based on the CH4 content. An analog actual value signal is read in and
At CH4 content (min) % The minimum power value is assigned to this CH4 value.
If the CH4 value undershoots the minimum limit value, the
Power at min % power is limited to this value. The limit is calculated on a
linear slope between the minimum and maximum values.
At CH4 content (max) % The maximum power value is assigned to this CH4 value.
If the CH4 value overshoots the maximum limit value, the
Power at max % power is limited to this value. The limit is calculated on a
linear slope between the minimum and maximum values.
Note
The values can only be modified at and above a specific user level (service)!
DK-BA-0005 / V01 / 06.10.2009 73

Pos: 10.62.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Gasbehälter @ 2\mod_1233676106944_101.doc @ 50739 @ 2
5.31 Additional function: Gas tank (optional)

Pos: 10.62.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Gasbehälter-007 @ 6\mod_1245313159011_101.doc @ 167933 @
Pos: 10.62.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Gasbehälter-001 @ 3\mod_1234185574510_101.doc @ 58285 @
Gas tank control is divided into several areas:

 Torch
 Start enable for the engine based on the fill level/gas pressure
 Power limitation based on the fill level/gas pressure
Note
Note
 Either an analog signal (standard) or digital signals (3 contacts) are used for evaluation
purposes.
Combining the two makes no sense and is therefore not possible!
 All parameters have to be defined by the customer.
74 DK-BA-0005 / V01 / 06.10.2009

Gas tank (fill level/pressure): Start enable via digital contact:

The module is enabled or shut down based on the fill level/pressure. Two digital transmitters (OFF/ON) are read in
for this purpose.
If the "ON" contact is pending, this time will elapse. The

Switch-on delay s module is not enabled until this time has elapsed and the
signal is pending.
If the "OFF" contact is pending, this time will elapse. The
Switch-off delay s module is not disabled until this time has elapsed and the
signal is pending.
Gas tank (fill level/pressure): Start enable via analog signal:

The module is enabled or shut down based on the fill level/pressure. An analog actual value signal is read in and

Value to switch on %
elapse.
If the limit value is exceeded, this time elapses. The
Switch-on delay s module is not enabled until this time has elapsed and the
limit value is exceeded.
Value to switch off %
elapse.
If the limit value is undershot, this time elapses. The
Switch-off delay s module is not disabled until this time has elapsed and the
limit value is undershot.
Gas tank (fill level/pressure): Power limitation via digital contacts:

The power of the engine is limited based on the fill level/pressure. A third switch is read in for this purpose (OFF,
ON and maximum power value, minimum power value).
When the switch responds (ON and maximum power

Power at max %
value), the power is set to this setpoint.
When the switch responds (minimum power value) and
Power at min % the switch is not active (ON and maximum power value),
the power is set to this setpoint.
DK-BA-0005 / V01 / 06.10.2009 75

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

The power of the engine is limited based on the fill level/pressure. An analog actual value signal is read in and
The minimum power value is assigned to this fill

At fill level/pressure min %
level/pressure value.
If the fill level/pressure undershoots the minimum limit
value, the power is limited to this value. The limit is
Power at min %
calculated on a linear slope between the minimum and
maximum values.
The maximum power value is assigned to this fill
At fill level/pressure max %
level/pressure value.
If the fill level/pressure overshoots the maximum limit
value, the power is limited to this value. The limit is
Power at max %
calculated on a linear slope between the minimum and
maximum values.
Gas tank torch control (fill level/pressure): Enable via analog signal:
The torch is enabled or shut down based on the fill level/pressure. An analog actual value signal is read in and

Value to switch on %
elapse.
If the limit value is exceeded, this time elapses. The torch
Switch-on delay s is not enabled until this time has elapsed and the limit
value is exceeded.
Value to switch off %
elapse.
If the limit value is undershot, this time elapses. The torch
Switch-off delay s is not disabled until this time has elapsed and the limit
value is undershot.
76 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.64.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-NetzbezugsRegelung @ 2\mod_1233676199825_101.doc @ 50782 @ 2
5.32 Additional function: Grid feed-in control

Pos: 10.64.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Netzbezugsregelung-006 @ 6\mod_1245315372954_101.doc @ 168019 @
01 Power rail
02 Busbar
03 Power, grid supply
04 Generator power
05 Generator
06 Consumer power
There are three ways of regulating the grid supply power:

 System draws power from the grid.
 System feeds power into the grid.
 Regulation to zero load (zero load regulation) at the grid supply point.
The actual value signal at the grid supply point is a "+/- signal" (e.g. -2000 kW to +2000 kW).
The signal is evaluated as follows:

 Generator power < Consumer power: signal is positive (+), system is drawing power from the grid.
 Generator power < Consumer power: signal is negative (-), system is feeding power into the grid.
 Generator power = Consumer power: signal is zero, system is neither feeding power into nor drawing
power from the grid.
DK-BA-0005 / V01 / 06.10.2009 77

It is also possible to set a start enable for the module based on the grid supply power.
The engine is only enabled if the parameterisable switch-on threshold is exceeded.
The same applies for the switch-off threshold.
This means that the use of the system can be optimised (peak currents can be avoided, for example).
Note
Note
In the case of both functions (grid feed-in control and start enable), you must check that they do not
cancel each other out (e.g. grid feed-in control should be set to a value which has previously been
set as the system's deselection point).
78 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.64.8 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Netzbezugsregelung-003 @ 3\mod_1234188563412_101.doc @ 58583 @
Status messages:
 Active:
This lights up to indicate that grid feed-in control has been activated.
 Power to grid:
This lights up to indicate that the system is feeding power into the grid.
 Power from grid:
This lights up to indicate that the system is drawing power from the grid.
 Dead zone:
This lights up to indicate that the system deviation is less than the dead zone.
 Setpoint max.:
This lights up to indicate that the calculated setpoint has reached the maximum permissible setpoint
for the power controller. The maximum setpoint (%) is displayed in the power controller parameters.
The setpoint is specified in the module parameters and cannot be modified.
 Setpoint min.:
This lights up to indicate that the calculated setpoint has reached the minimum permissible setpoint for
the power controller.
The minimum setpoint (%) is displayed in the power controller parameters.
The setpoint is specified in the module parameters and cannot be modified.
 Start enable
If the setpoint/actual value deviation is negative, the system is feeding power into the grid; if it is positive, the
system is drawing power from the grid.
DK-BA-0005 / V01 / 06.10.2009 79

Pos: 10.64.10 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Netzbezugsregelung-004 @ 3\mod_1234188814481_101.doc @ 58595 @
Parameters for grid feed-in control:
The power at the grid supply point is regulated to this

Setpoint KW value. If the value is negative, the system should be
feeding power into the grid.
If the system deviation (xd) is less than this value, the
setpoint for the power controller will not undergo further
Dead zone KW
changes.
This prevents system oscillation.
This value specifies by how many percent the setpoint for
the power controller is modified per second.
The setpoint for the power controller is only modified if the
Increment KW
system deviation is greater than the dead zone. The
increment must be set to a value less than the value of
the dead zone.
This is the idle time between two changes to the power
Pause time s
controller's setpoint.
80 DK-BA-0005 / V01 / 06.10.2009

Parameters for start enable:
Selection without delay.

X1 KW If the actual value overshoots this limit, the engine is
enabled without delay.
Selection with delay.
If the actual value overshoots this limit and is less than the
value to switch on without delay, the engine is enabled
X2 KW
subject to a delay. The delay time is calculated on a linear
slope between the value to switch on without delay and
the value to switch on with delay.
Delay time for selection.
This time is calculated on a linear slope between the
value to switch on without delay and the value to switch
Y1 s
on with delay. The closer the current actual value is to the
value to switch on without delay, the shorter the delay
time.
Deselection with delay.
If the actual value undershoots this limit, the engine is
disabled subject to a delay.
X3 KW
The delay time is calculated on a linear slope between the
value to switch off without delay and the value to switch
off with delay.
Deselection without delay.
X4 KW If the actual value undershoots this limit, the engine is
disabled without delay.
Delay time for deselection.
Y2 s
off with delay. The closer the current actual value is to the
value to switch off without delay, the shorter the delay
time.
The limit values for selection and deselection must get smaller from left to right (on the X axis). If they do not, a
default value is activated (+400, +300, -300, -400).
DK-BA-0005 / V01 / 06.10.2009 81

Pos: 10.66.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-AbgasBypass @ 2\mod_1233676267908_101.doc @ 50795 @ 2
5.33 Additional function: Exhaust-/ Butterfly valves (optional)

Pos: 10.66.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-AbgasBypass-003 @ 6\mod_1245318871968_101.doc @ 168139 @
Pos: 10.66.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-AbgasBypass-001 @ 3\mod_1234191307259_101.doc @ 58659 @
The exhaust butterfly valve is opened when the module starts up. It is needed in multi-module systems to prevent
combustion air flowing back to modules which have been deselected.
The task of the butterfly valve is to divert the hot exhaust gas via an exhaust gas heat exchanger at low heat
consumption levels in order to prevent the heating water overheating.
Bypass mode can be activated by means of the parameterisable limit value or by hand (via the selection button).
Bypass mode can also be activated remotely via an optional input. In this case butterfly valve 2 is opened first and
butterfly valve 1 does not close until the "open" limit switch responds.
All butterfly valves can also be operated by hand.
Pos: 10.66.4 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-AbgasBypass-002 @ 3\mod_1234191399939_101.doc @ 58711 @
Parameters for bypass mode:
When the limit value is exceeded, bypass butterfly valve 2

Limit value for bypass mode °C
opens first and then bypass butterfly valve 1 closes.
When the limit value is undershot by the hysteresis,
Hysteresis for bypass mode °C
bypass mode is deactivated.
Note
82 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.68.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-WärmebetriebMotor @ 2\mod_1233676332802_101.doc @ 50808 @ 2
5.34 Additional function: Engine heat operation (optional)

Pos: 10.68.2 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-WärmebetriebMotor-001 @ 3\mod_1234192228905_101.doc @ 58753 @
Only start enable based on water temperature:
Pos: 10.68.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-WärmebetriebMotor-001 @ 3\mod_1234192371882_101.doc @ 58765 @
The module is started or stopped automatically if the temperature overshoots or undershoots various limit values.
Delay times can also be entered in addition.
Furthermore, the selection limit values can be offset by the outdoor temperature or a reduction.
Note
DK-BA-0005 / V01 / 06.10.2009 83

Parameters for start request:
Selection without delay If the actual value undershoots this limit, the engine is
°C
X1 enabled without delay.
If the actual value undershoots this limit and is greater

than the value to switch on without delay, the engine is
Selection with delay enabled subject to a delay.
°C
X2 The delay time is calculated on a linear slope between the
on with delay.
Delay time for selection value to switch on without delay and the value to switch
s on with delay. The closer the current actual value is to the
Y1 value to switch on without delay, the shorter the delay
time.
Deselection without delay If the actual value overshoots this limit, the engine is
°C
X4 disabled without delay.
limit value without delay, the engine is disabled subject to
Deselection with delay a delay.
°C
off with delay.
Delay time for value to switch off without delay and the value to switch
deselection s off with delay. The closer the current actual value is to the
Y2 value to switch off without delay, the shorter the delay
time.
84 DK-BA-0005 / V01 / 06.10.2009

Floating: Start enable and power regulation based on water temperature:
The controller takes the form of a PI controller, whose output variable can modify the module power between 50%
(setpoint min.) and 100%.
The limit values for the start enable can be influenced using the outdoor temperature characteristic.
Note
DK-BA-0005 / V01 / 06.10.2009 85

Example with heating water return temperature as setpoint:
Heating water return temperature: Separate sensor in system
 Start enable (values correspond to the current screen):

If the module is stationary and the heating water return temperature (actual value) falls below 66 °C (X2 on
the screen), there will be a delay of 30 seconds (Y1 on the screen) before the module is selected. The further
the temperature falls (direction X1), the faster the module will be selected.
 Control (values correspond to the current screen):

When the module is running, the setpoint power is calculated based on the heating water return temperature
in the PI controller. The current temperature actual value is also displayed. An attempt is made to control the
heating water return temperature to the "setpoint" (70 °C in the example); in other words, as long as the
heating water actual value is less than the heating water setpoint, the module power setpoint (setpoint
power) is increased corresponding to the control parameters (up to a maximum of 100%). If the heating
water actual value rises above the heating water setpoint, the module power setpoint is reduced again (down
to setpoint min.).
Special feature "Heat operation with limiting function"
In this operating mode, the calculated setpoint continues to be limited by grid feed-in control. The setpoint is
not increased further, like the current calculated setpoint for grid feed-in control.
 Shutdown (start enable is deactivated):

The module is deselected as soon as the heating controller signals "Setpoint min." and the alarm message
"Heating water temperature > Limit value 1" is pending. This maximises the running time of the module.
86 DK-BA-0005 / V01 / 06.10.2009

Power regulation indicators:
This LED turns green as soon as regulation is activated

Control active (start enable by heat operation and operation in parallel
with the grid active).
This LED turns green when the start ramp is active and
Warm-up time
the warm-up time is running.
This LED turns green as soon as the calculated module
Setpoint min.
setpoint power matches the "Setpoint min.".
This LED turns green as soon as the calculated module
100 % setpoint power matches the "Setpoint max." (in other
words, is equal to 100%).
If grid feed-in control is not active, this indicator is
deactivated.
In heat operation with limiting this LED turns green as
Grid feed-in contr. soon as the grid feed-in control power falls below the
power of the floating heat operation.
The calculated grid feed-in control power continues to be
displayed underneath.
The current heating water temperature setpoint is
displayed here.
Setpoint °C
This is increased from the start setpoint to the setpoint
during the warm-up time.
The current actual value at the temperature sensor for the
Actual value °C
heating water temperature is displayed here.
The difference between the setpoint and the actual value
Deviation setpoint/value °C
is displayed here actual value (setpoint – actual value).
Setpoint power % The module power setpoint is displayed here.
Actual value power % The module power actual value is displayed here.
DK-BA-0005 / V01 / 06.10.2009 87

Parameters for power regulation:
This parameter corresponds to the setpoint (heating water

temperature) for the controller.
Setpoint °C On completion of the start ramp the controller adjusts the
module power in order to set the heating water
temperature to this value.
Once the controller has been activated the setpoint
temperature is increased along a start ramp.
Start setpoint °C
This start ramp (for the temperature setpoint) starts at this
value.
During the warm-up time the temperature setpoint is
increased from the start setpoint to the actual setpoint.
Warm-up time s
Only once this time has elapsed is the value controlled to
this temperature, which was entered as the "Setpoint".
deviation the manual variable (module power setpoint) is
KP opened or closed by this factor (e.g. system deviation +5
°C, KP=6: proportional component of manual variable is
30%).
the module power.
Tn s output value of the P controller at these intervals. An
excessively low reset time may result in oscillation of the
manual variable for module power.
Corresponds to the minimum power at which the module
Setpoint min. %
may operate.
88 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.70.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-WärmebetriebKessel @ 2\mod_1233676400604_101.doc @ 50831 @ 2
5.35 Additional function: Boiler heat control (optional)

Pos: 10.70.2 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-WärmebetriebKessel-001 @ 3\mod_1234248921755_101.doc @ 58873 @
Pos: 10.70.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-WärmebetriebKessel-001 @ 3\mod_1234249062991_101.doc @ 58885 @
The boiler is started or stopped automatically if the temperature overshoots or undershoots various limit values.
Delay times can also be entered in addition.
Furthermore, the limit values for selection/deselection can be offset by the outdoor temperature or a reduction.
Note
DK-BA-0005 / V01 / 06.10.2009 89

Pos: 10.70.6 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-WärmebetriebKessel-002 @ 3\mod_1234249141984_101.doc @ 58897 @
Parameters for start request, boiler:
Selection without delay If the actual value undershoots this limit, the boiler is
°C
X1 enabled without delay.
If the actual value undershoots this limit and is greater

than the value to switch on without delay, the boiler is
Selection with delay enabled subject to a delay.
°C
on with delay.
Delay time for selection value to switch on without delay and the value to switch
s on with delay. The closer the current actual value is to the
Y1 value to switch on without delay, the shorter the delay
time.
Deselection without delay If the actual value overshoots this limit, the boiler is
°C
X4 disabled without delay.
limit value without delay, the boiler is disabled subject to a
Deselection with delay delay.
°C
off with delay.
Delay time for value to switch off without delay and the value to switch
deselection s off with delay. The closer the current actual value is to the
Y2 value to switch off without delay, the shorter the delay
time.
90 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.72.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Außentemperaturverschiebung @ 2\mod_1233676458561_101.doc @ 50844 @ 2
5.36 Additional function: Outdoor temperature offset (optional)

Pos: 10.72.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Außentemperaturverschiebung-001 @ 3\mod_1234249450134_101.doc @ 58909 @
The outdoor temperature offset can be used for heat operation (engine and boiler).
This function influences the switching points for the enable.
Pos: 10.72.3 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-Außentemperaturverschiebung-001 @ 3\mod_1234249544160_101.doc @ 58921 @
The characteristic is used to calculate an offset (positive or negative) based on the current outdoor temperature,
which is then added to the switching points. The offset can be adapted to prevailing conditions along 3 slopes. 4
parameter sets are required for this purpose.
 The limit values for the X axis (outdoor temperature limit values) must increase from left to right.
Furthermore, the switching points can be offset downwards by a configurable value by means of a reduction
(activated via an optional input).
DK-BA-0005 / V01 / 06.10.2009 91

Parameters for outdoor temperature:
X1 °C Outdoor temperature value for offset value Y1

Y1 °C Offset value for outdoor temperature value X1
Parameters for reduction:
Reduction value °C All switching points are offset downwards by this value.
92 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.74.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Pufferspeicher @ 2\mod_1233676520393_101.doc @ 50857 @ 2
5.37 Additional function: Heating water reservoir (optional)

Pos: 10.74.2 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-Pufferspeicher-001 @ 3\mod_1234250088367_101.doc @ 58967 @
Pos: 10.74.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Pufferspeicher-001 @ 3\mod_1234250183752_101.doc @ 58979 @
The module is started or stopped using heating water reservoir control.

For this purpose, 4 sensors are selected in the heating reservoir. The screen shows whether the reservoir is filling
or emptying.
Once the start enable has been set for the module, the configurable warm-up time elapses.
Once this time has elapsed, other heat generators (e.g. boilers) can be enabled for activation.
If the gradient evaluation function detects that the reservoir is already being refilled, the selection of other heat
generators will be disabled.
Note
DK-BA-0005 / V01 / 06.10.2009 93

Pos: 10.74.6 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Pufferspeicher-002 @ 6\mod_1245326089907_101.doc @ 168330 @
Parameters for heating water reservoir:
PT4: Selection without If the actual value undershoots this limit, the engine is
°C
delay enabled without delay. The reservoir is empty.
If the actual value undershoots this limit, the engine is
PT5: Selection with delay °C
enabled subject to a delay (see Delay time).
PT5: Delay time for If the limit from PT5 is undershot, this timer starts to run.
s
selection Once the timer has elapsed, the engine is enabled.
PT7: Deselection without If the actual value overshoots this limit, the engine is
°C
delay disabled without delay. The reservoir is full.
If the actual value overshoots this limit and undershoots
PT6: Deselection with
°C the limit value from PT7, the engine is disabled subject to
delay
a delay (see Delay time).
PT6: Delay time for If the limit from PT6 is overshot, this timer starts to run.
s
deselection Once the timer has elapsed, the engine is disabled.
At the end of the warm-up time other generators can be
Warm-up time min
enabled.
94 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.76.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-Zeitschaltuhr @ 2\mod_1233676641854_101.doc @ 50890 @ 2
5.38 Additional function: Timer (optional)

Pos: 10.76.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-Zeitschaltuhr-001 @ 3\mod_1234250767065_101.doc @ 59023 @
The mode of operation of the system at certain times of day or on certain days of the week can be influenced using
the timer.
 Up to 5 operating modes can be activated on one system!
Pos: 10.76.3 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-Zeitschaltuhr-001 @ 3\mod_1234250829499_101.doc @ 59035 @
Operation:
The days of the week with the current operating mode settings for certain times of the day appear at the top of the
screen. The various operating modes are displayed in different colours.
Up to 8 switching points can be set per day.
The key listing the available operating modes appears underneath the days of the week.
The current operating mode is shown on the right at the very bottom of the screen.
The three buttons on the bottom left can be used to select the following functions:
1 Time program The system's operating modes are controlled by the timer.
The time program is disabled.

2 Always on
The module is always activated.
The time program is disabled.
3 Always off
The module is disabled.
DK-BA-0005 / V01 / 06.10.2009 95

Setting a switching point for a day of the week:

To set the switching points, click the bar representing the required day of the week.
A data entry window appears:
Pos: 10.76.7 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-Zeitschaltuhr-002 @ 3\mod_1234251153100_101.doc @ 59071 @
The activated switching points and the corresponding operating mode selected are displayed on the left-hand side.
Delete switching point:

To delete a switching point, press the "Delete" button.
Adding switching points (up to 8):

To enter a new switching point, press the "h" and "min" input fields.
Then press the button for the corresponding operating mode (colour keys) and the "Accept" button.
This adds the required switching point to the day.
 To activate the set values you need to press the "Save" button.
The button is only becomes active if data has been modified.
 To get an overview, press the "Home" button to return to the main screen.
96 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.78.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-SMSEmail @ 2\mod_1233676891588_101.doc @ 50949 @ 2
5.39 Additional function: SMS / E-mail (optional)

Pos: 10.78.2 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-SMSEmail-001 @ 3\mod_1234255234219_101.doc @ 59189 @
This function can be used to send a message via e-mail when alarms or status messages are accumulated.
These e-mails are collected on the MTU Onsite Energy server, from where they are forwarded to the customer
addresses entered (e-mail or SMS).
The automatic maintenance request can also be sent in this way.
 In the case of transmission via e-mail, all currently active messages are grouped and sent in a single
message. In the case of SMS recipients, all active messages are transmitted individually (on account
of character length). Therefore, you need to proceed very carefully when selecting which messages to
send, not least because of the costs incurred.
Requirements:
 See separate document "User manual for remote diagnostics system 2008".
Operating data transmission (optional auxiliary feature):

The most important operating data (e.g. operating hours, start counters, other counter readings, overview of alarm
messages accumulated) is sent to the address registered with MTU Onsite Energy once a day automatically via e-
mail.
 Operating data cannot be sent via SMS as it takes the form of a long text document!
DK-BA-0005 / V01 / 06.10.2009 97

Pos: 10.78.4 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-SMSEmail-001 @ 3\mod_1234255610590_101.doc @ 59221 @
Operation – Overview window:
The first text box in the overview window shows the SMS messages which have accumulated and are to be sent;
the second shows the messages accumulated for despatch via e-mail. The status of the transmission process is
recorded in the third text box
When the pending messages have been processed and sent, they are deleted from the first two text fields.
This occurs even if message transmission has failed (e.g. because the attempt to establish a long-distance data
transmission connection to the provider has failed).
Both successful and failed transmission attempts are recorded in the status window. This window is deleted once a
day at midnight.
There are buttons at the bottom of the overview window which enable the SMS/e-mail client to be configured.
98 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.78.7 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-SMSEmail-002 @ 3\mod_1234256300660_101.doc @ 59245 @
Operation – Selecting status messages to be sent via SMS/e-mail:
Actuating the operation message button in the overview window brings up the page where the notification options
for the operation messages can be set.
The first column shows whether the corresponding operation message for notification by SMS is selected or not. If
the message is selected, the cell appears on a green background and "YES" is displayed as the text.
If messages have not been selected, the corresponding line is white and "NO" is displayed as the text.
In the second column you can make the selection for notification by e-mail for the corresponding operation
message. You can change the selection by touching the corresponding cell. However, you can make changes only
if you have logged in to the main operation menu.
The four buttons on the right-hand edge of the table can be used to move the table's contents up and down to edit
all the messages.
Operation – Selecting alarm messages to be sent via SMS/e-mail:

See Selecting status messages to be sent!
DK-BA-0005 / V01 / 06.10.2009 99

Pos: 10.80.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Servicemenü @ 2\mod_1233676947451_101.doc @ 50962 @ 2
5.40 Service menu

Note
The menu is available for service purposes and can only be opened by authorised persons.
100 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.82.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Zusatzfunktion-ExterneKommunikation @ 2\mod_1233677012502_101.doc @ 50975 @ 2
5.41 Additional function: External communication (optional)

Pos: 10.82.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-ExterneKommunikation-004 @ 6\mod_1245410213936_101.doc @ 168573 @
Pos: 10.82.3 /Dokumentation/Beschreibung/BA/MMC/MMC_allgemein/TX-ExterneKommunikation-001 @ 3\mod_1234341046197_101.doc @ 59873 @
The active communication protocol is displayed. The current communication status is also displayed. This can be
helpful when troubleshooting (see also our "Technical interface descriptions").
Click the active communication (e.g. Profibus) to access the parameter window:
DK-BA-0005 / V01 / 06.10.2009 101

All parameters used are displayed in this window.

You can change the address here, for example. Press the "Write Parameter" button to activate the data.
You can jump to the Simulation window for test purposes. To do this, press the "Simulation" button.
Note
If activated, simulation intervenes directly in the data exchange between the MMC and the connected
external controller.
102 DK-BA-0005 / V01 / 06.10.2009

Simulation is activated by pressing the "active" button. All data points are then set to "0" and the data areas
selected for simulation are replaced by the data selected in the simulation window.
Simulation of output data: Data which is sent to the external interface (status):
 Select the bit information to be simulated with the aid of the interface description.
 Enter the required status no. (e.g. alarm messages 1-16).
 Set or reset the required bit (e.g. set alarm message 7).
 The receiving station can now be checked to see if the signal arrived correctly.
When simulating analog values you also need to enter the status number of the required value (see Interface
description). You can then enter the simulation setpoint.
Checking input data: Data which is received from the external interface (controls):
To check the data arriving at the MMC, simply enter the relevant control number. The corresponding bit pattern or
the equivalent analog value is then displayed.
Note
Once testing is complete, simulation has to be deactivated by pressing the "active" button. Simulation
is shut down automatically after 120 minutes.
DK-BA-0005 / V01 / 06.10.2009 103

Pos: 10.84.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-Schnittstellenprotokoll @ 2\mod_1233677085538_101.doc @ 50988 @ 2
5.42 Interface protocol - general

Pos: 10.84.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Schnittstellenprotokoll-002 @ 6\mod_1245411840358_101.doc @ 168652 @
The module control can be equipped with various interface protocols (e.g. Profibus DP).
For the link with the peripherals the corresponding interface modules then have to be installed in the MMC.
The data protocol is the same for all interface protocols except Profibus DP.
All data (temperatures, alarm messages, status messages, etc.) is available in this protocol.
The communication interfaces are set up for bidirectional operation.
 See separate description

104 DK-BA-0005 / V01 / 06.10.2009

Pos: 10.86.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-MGraphEinzelkanal @ 2\mod_1233677248080_101.doc @ 51014 @ 2
5.43 M-Graph: Single channel

Pos: 10.86.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-MGraphEinzelkanal-002 @ 6\mod_1245833441722_101.doc @ 170139 @
This online recorder supports the mapping of all available measured values in the form of graphs.
Up to 100 channels are available. A maximum of two channels can be displayed at the same time.
All values are updated to the exact minute.
Select channels:
The channels which are currently being displayed are shown at the bottom of the screen.
Touch the arrow at the end of the display menu to open a menu in which a different channel can be selected.
Touch the colour symbol to hide the corresponding channel.
Pos: 10.86.5 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-MGraphEinzelkanalTagesverlauf-002 @ 3\mod_1234345154676_101.doc @ 60103 @
Display range of the time axis (X):

The time axis is always set to 24 hours. You can scroll back up to 31 days.
Scaling of measurement ranges (Y):

The scale of the Y adjusts automatically to the maximum and minimum values.
Zoom:
Use the Zoom button to zoom in on a section of the graph.
Touch the Zoom button once; it turns green.
Then use the mouse to draw a rectangle on the graph. The display then zooms in on this section.
To deactivate the zoom, touch the "Zoom" button again.
Pos: 10.86.8 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-MGraph-003 @ 3\mod_1234345408817_101.doc @ 60127 @
Activation:
The channels are written to a database automatically (time period of 31 days).
DK-BA-0005 / V01 / 06.10.2009 105

Pos: 10.88.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-MGraph Anlage Sekundengraph @ 6\mod_1245834693976_101.doc @ 170309 @ 2
5.44 M-Graph: System diagram per second

Pos: 10.88.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-MGraphAnlageSekundengraph-006 @ 6\mod_1247058839466_101.doc @ 176612 @
This online recorder supports the mapping of all available measured values in the form of graphs.
A maximum of 8 channels can be displayed at the same time. All values are updated to the exact second.

The last 15 minutes are displayed.

Zoom:
Activation:
The channels are entered in a 15-minute circular buffer automatically.
106 DK-BA-0005 / V01 / 06.10.2009

Configuration:
Touch the "Config." button to switch to the configuration screen.
Up to five configurations can be created.
Up to 8 channels can be selected per configuration, four of these for each Y axis.
For this purpose a number must be entered under which the configuration is saved (max. 5).
Once you have entered the name of the configuration you have to select the channels. Then click the "Save
configuration" button to save the configuration.
Pos: 10.88.12 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-MGraphEreignisrecorder-004 @ 6\mod_1245842519832_101.doc @ 170683 @
To display another configuration on the graph, select the corresponding number and touch the "Active
configuration" button. The corresponding configuration number then appears in the "Active" field.
DK-BA-0005 / V01 / 06.10.2009 107

Pos: 10.90.1 /Dokumentation/ÜB-Überschriften/1.1/ÜB-MGraph Anlage Tagesverlauf @ 6\mod_1245841047322_101.doc @ 170605 @ 2
5.45 M-Graph: System intraday

Pos: 10.90.2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-MGraphAnlageTagesverlauf-001 @ 6\mod_1245840897778_101.doc @ 170579 @
This online recorder supports the mapping of up to eight significant measured values on a graph at the same time.
All values are updated to the exact minute.
Pos: 10.90.4 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-MGraphEinzelkanalTagesverlauf-002 @ 3\mod_1234345154676_101.doc @ 60103 @

The time axis is always set to 24 hours. You can scroll back up to 31 days.

Zoom:
Pos: 10.90.7 /Dokumentation/Beschreibung/BA/MMC/MMC_400/TX-MGraph-003 @ 3\mod_1234345408817_101.doc @ 60127 @
Activation:
The channels are written to a database automatically (time period of 31 days).
Switch configuration:
To display another configuration on the graph, select the corresponding number here.
108 DK-BA-0005 / V01 / 06.10.2009

Configuration:
Touch the "Config." button to switch to the configuration screen.
Up to five configurations can be created.
Up to 8 channels can be selected per configuration, four of these for each Y axis.
For this purpose a number must be entered under which the configuration is saved (max. 5).
Once you have entered the name of the configuration you have to select the channels. Then click the "Save
configuration" button to save the configuration.
DK-BA-0005 / V01 / 06.10.2009 109

=== Ende der Liste für Textmarke Inhalt ===
110 DK-BA-0005 / V01 / 06.10.2009

DK-BA-0005 / V01 / 06.10.2009 111
MTU Onsite Energy GmbH
Postfach 10 21 30 • 86011 Augsburg
Dasinger Str. 11 • 86165 Augsburg
Tel.: +49 (0)821 / 7480-0
Fax: +49 (0)821 / 7480-119
Internet: http://www.mtu-online.com
Europe / Middle East / Africa / Latin America Asia / Australia / Pacific USA / Canada / Mexico
MTU Friedrichshafen GmbH MTU Asia Pte. Ltd. MTU Detroit Diesel, Inc.
88040 Friedrichshafen 1, Benoi Place 13400 Outer Drive West
Germany Singapore 629923, Detroit, Michigan 48239,
Republic of Singapore USA
Phone +49 7541 90 7001 Phone +65 6861 5922 Phone +1 313 592 7000
Fax +49 7541 90 7081 Fax +65 6861 3615 Fax +1 313 592 7788
regionalcenter1@mtu-online.com regionalcenter2@mtu-online.com regionalcenter3@mtu-online.com
www.mtu-online.com www.mtu-online.com www.mtu-online.com
112 DK-BA-0005 / V01 / 06.10.2009

DK Ba 0005 - GB, English

Uploaded by

Copyright:

Available Formats

You might also like

DK Ba 0005 - GB, English

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DK Ba 0005 - GB, English

Uploaded by

Copyright:

Available Formats

OPERATING INSTRUCTION

DK-BA-0005 / V01 / 06.10.2009

©2009 MTU Onsite Energy GmbH

Original document was created in German.

Subject to technical alterations in the interest of further development.

2 DK-BA-0005 / V01 / 06.10.2009

DK-BA-0005 / V01 / 06.10.2009 3

5.9 Electrical data .........................................................................................................................................30

4 DK-BA-0005 / V01 / 06.10.2009

5.39 Additional function: SMS / E-mail (optional)........................................................................................... 97

DK-BA-0005 / V01 / 06.10.2009 5

Pos: 2 /Dokumentation/Beschreibung/BA/MMC/MMC_4000/TX-Update Listing-0005 @ 6\mod_1250686770380_0.doc @ 185143 @ 1

Update Listing DK-BA-0005

Anpassung auf MTU Baureihe 4000 (Phase 3)

Anpassung der Cosphi-Regelung

Update, Eingabe in Docuglobe

6 DK-BA-0005 / V01 / 06.10.2009

1.1 System description “MMC”

 Industrial PC (IPC) with touch screen and various interfaces,

1.2 "MTU Engine Management" system description

1.3 Safety instructions

1.4 Safety chain

The safety chain is equipped with 2 tested category 2 safety combinations.

DK-BA-0005 / V01 / 06.10.2009 7

1.6 Selectivity of protective devices

1.7 Shielded lines

 The shield must be fitted very close to the connecting point.

1.8 Diagram documentation

1.10 Battery cutoff

8 DK-BA-0005 / V01 / 06.10.2009

1.11 Critical malfunction messages

 087 - Generator circuit-breaker will not open

 088 - Generator circuit-breaker will not open – trailing mode active

DK-BA-0005 / V01 / 06.10.2009 9

2.1 Start sequence

 Start command (local/remote)

 No start command to MTU Engine Management

 Start command to MTU Engine Management

 Start abort phase 1 by MTU Engine Management

Phase 2  Open gas valves (request from MTU Engine Management)

 Start abort phase 2 by MTU Engine Management

10 DK-BA-0005 / V01 / 06.10.2009

 Rated speed reached (message from MTU Engine Management)

 Generator voltage > limit value

Start abort phase 3

 Enable synchronisation (message from MTU Engine Management)

Start precondition 5  Generator circuit-breaker is ON

Start abort phase 4

Operation in parallel with the grid: Monitoring of power regulation, ramp

Pos: 4.3 /OX-Seitenumbruch @ 0\mod_1218433559331_0.doc @ 255 @

DK-BA-0005 / V01 / 06.10.2009 11

2.2 Stop sequence

Phase 0  Genset in operation and stop pending

Stop precondition 0  Slow stop (ramp function)

 Quick stop (jump to phase 2 immediately)

Phase 1  Genset is relieved of load (ramp function)

 Open generator circuit-breaker

Module ready to start