PPC Gen Controller

INSTRUCTION MANUAL
Programmable Power Controller

( GEN : 3 SETS )
KT-PPC
REV DATE REASON MADE CHECKED APPROVED
V1.0E 1994.11. Beginning D.H.Hwang S.W.Jeong J.Y.Chung
V1.1E 2006.11.20. Change of document form D.H.Hwang S.W.Jeong J.Y.Chung
V1.2E 2007.08.17 Add REMARK C.Y.Jeong S.W.Jeong J.Y.Chung
V1.3E 2008.11.17 Add load balance abnormal function C.Y.Jeong S.W.Jeong J.Y.Chung
V1.4E 2009.02.02. Add troubles and correcting measures C.Y.Jeong S.W.Jeong J.Y.Chung
V1.5E 2010.01.20. Add Product Storage Precautions C.Y.Jeong S.W.Jeong J.Y.Chung
V1.6E 2010.07.08. Changed Operating Temperature follow by ENV Test Report C.Y.Jeong S.W.Jeong J.Y.Chung
Document No. TIR9402-30-D01
210*297(mm) KTE CO., LTD TI-06(R0)
Downloaded from www.Manualslib.com manuals search engine

Instruction Manual of REV PAGE : 2 OF 25
Programmable Power Controller (KT-PPC) 1.6E Doc No: TIR9402-30-D01
TABLE OF CONTENT
1. SPECIFICATIONS........................................................................................................... 3
1.1. APPLICATIONS ...................................................................................................................3
1.2. GENERAL SPECIFICATIONS ..............................................................................................4
2. SYSTEM CONSTRUCTION ............................................................................................ 5
2.1. DIAGRAM OF POWER MANAGEMENT CONTROL SYSTEM (FOR SHIP) ........................5
2.2. DIAGRAM OF POWER MANAGEMENT CONTROL SYSTEM ............................................6
3. SYSTEM FLOW CHARTS .............................................................................................. 7
3.1. Auto Parallel Running by Heavy Load & Pref. Trip ...........................................................8
3.2. Auto Parallel Running Cancellation by Light Load...........................................................9
3.3. Auto Changeover by BUS No Voltage .............................................................................10
3.4. Auto Changeover by BUS Abnormal ............................................................................... 11
3.5. Auto Parallel Running by ACB Trip .................................................................................12
4. INPUT / OUTPUT SPECIFICATIONS ........................................................................... 13
4.1. TERMINAL INPUT 00 .........................................................................................................13
4.2. TERMINAL INPUT 01 .........................................................................................................14
4.3. TERMINAL OUTPUT 03 .....................................................................................................15
4.4. TERMINAL OUTPUT 04 .....................................................................................................16
5. INPUT / OUTPUT REFERENCE TABLES .................................................................... 17
6. INTERNAL SETTING & ADJUSTING ........................................................................... 21
6.1. INTERNAL SETTING TABLE .............................................................................................21
6.2. Panel Switch using method ..............................................................................................22
7. DIAGNOSTIC & TROUBLES AND CORRECTING MEASURES ................................. 23
8. EXTERNAL FORM ........................................................................................................ 24
9. PRODUCT STORAGE PRECAUTIONS ....................................................................... 25
210*297(mm) KTE CO., LTD TI-06(R0)

1. SPECIFICATIONS
1.1. APPLICATIONS
KT-PPC(Programmable Power Controller) optimizes the ship and ground power generation systems
and efficiently perform an active power management & control by controlling KT-ASD(Auto synchronizing
Device) and KT-PWC(Power Controller). Normally KT-PPC is designed to control 3 generators but you
can enlarge its capacity to maximum 5 generators with extension module.
AND self-diagnosis function lets you find out the cause of the errors in the case of problems, so it is
easy for you to maintain the power control system. You can build electric power control system for
various applications by modifying or changing the control program according to your system
configurations.
【 MODEL CLASSIFICATION 】
① KT-PPC (without Big Motor Starting function)
② KT-PPC-A (with Big Motor Starting function)
◈ MAIN FUNCTIONS
• Auto Parallel Running by Heavy Load & Pref. Trip
• Auto Parallel Running Cancellation by Light Load
• Auto Changeover by BUS NO Voltage
• Auto Changeover by BUS Abnormal
• Auto Parallel Running by ACB Trip
• Generator Engine Control ( Start / Stop)
• Big Motor Start Control
• Input / Output LED Display
• Self test & Error Display
• Load Balance Abnormal (RATING POWER X ±5%, DELAY TIME 120SEC.)
210*297(mm) KTE CO., LTD TI-06(R0)

1.2. GENERAL SPECIFICATIONS
Item Description
Power Source DC 24V ±20%
Current Consumption Max 1A / DC 24V

General
Operating temp : 0 ~ 55℃
Temperature range
Storing temp : -10℃ ~ 70℃
Specifications
Weight Approx. 5Kg
Communication RS-232c serial 1 port
Control system Intel 80c196kc 16Bit microcomputer
CPU Program system Assemble description system
Specification Program memory External 32K bytes(27c256) EPROM
Internal 256bytes RAM

Memory
External 32K bytes(28c256) EEPROM
Digital input : 48 Channel (on/off)
Input signal
Input / Output Analog input : 5 Channel (4 ~ 20mA)
Specification Contact output : 8 Channel('a" contact)
Output signal
Signal output : 32 Channel(positive signal)
210*297(mm) KTE CO., LTD TI-06(R0)

2. SYSTEM CONSTRUCTION
2.1. DIAGRAM OF POWER MANAGEMENT CONTROL SYSTEM (FOR SHIP)
<REMARK>
1. PWC : Generator power controller for ship.
2. Each PWC is used for controlling up to 3 generators
3. PWC can be connected up to max. 5 units by communication line.
210*297(mm) KTE CO., LTD TI-06(R0)

2.2. DIAGRAM OF POWER MANAGEMENT CONTROL SYSTEM
(WITH INCOMING POWER)
<REMARK>
One unit of PWC used for each generator.
(Maximum of 15 units can be used)
210*297(mm) KTE CO., LTD TI-06(R0)

3. SYSTEM FLOW CHARTS
3.1. Auto Parallel Running by Heavy Load & Pref. Trip

- Refer to Flowchart
3.2. Auto Parallel Running Cancellation by Light Load

3.3. Auto Changeover by BUS No Voltage

3.4. Auto Changeover by BUS Abnormal

3.5. Auto Parallel Running by ACB Trip

210*297(mm) KTE CO., LTD TI-06(R0)

3.1. Auto Parallel Running by Heavy Load & Pref. Trip
210*297(mm) KTE CO., LTD TI-06(R0)

3.2. Auto Parallel Running Cancellation by Light Load
210*297(mm) KTE CO., LTD TI-06(R0)

3.3. Auto Changeover by BUS No Voltage
210*297(mm) KTE CO., LTD TI-06(R0)

3.4. Auto Changeover by BUS Abnormal
210*297(mm) KTE CO., LTD TI-06(R0)

3.5. Auto Parallel Running by ACB Trip
210*297(mm) KTE CO., LTD TI-06(R0)

4. INPUT / OUTPUT SPECIFICATIONS
4.1. TERMINAL INPUT 00
01 (+)
AN1 No.1 GEN Power
02 (-)
03 (+)
AN2 No.2 GEN Power
04 (-)
05 (+)
AN3 No.3 GEN Power
06 (-)
07 (+)
AN4 No.4 GEN Power
08 (-)
09 (+)
AN5 No.5 GEN Power
10 (-)
11 GND
12 GND
13 F.G Frame Ground
14 F.G Frame Ground
15 Unused I
16 Unused N
17 Unused P
18 Unused U
19 Unused T
20 Unused
21 Unused 0
22 Unused 0
23 Unused
24 Unused
25 No.1 GEN Auto mode select
28 No.1 GEN Abnormal Reset
31 No.1 GEN (ENG. START SW.)
34 No.1 GEN (ENG. STOP SW.)
210*297(mm) KTE CO., LTD TI-06(R0)

4.2. TERMINAL INPUT 01
01 No.1 GEN (ACB OPEN SW.)

04 Auto Load Sharing
05 No.1 GEN Ready to Start
08 No.1 GEN Run
09 No.2 GEN Run
10 No.3 GEN Run
11 No.1 GEN Stop
12 No.2 GEN Stop
13 No.3 GEN Stop
14 No.1 GEN ACB Close
15 No.2 GEN ACB Close I
16 No.3 GEN ACB Close N
17 GEN. Voltage build up P
18 Unused U
19 Unused T
20 PPC Run
21 No.1 GEN ACB Trip (OCP, RPR) 0
22 No.2 GEN ACB Trip (OCP, RPR) 1
23 No.3 GEN ACB Trip (OCP, RPR)
24 Heavy Load (PWC)
25 Light Load (PWC)
26 High Power (PWC)
27 ACB Open Command (PWC)
28 Bus Abnormal (PWC)
29 ACB non Close (ASD)
30 Auto Synchro Fail (ASD)
31 PREF. Trip
32 Bus No Volt
33 REQU.1
34 REQU.2
35 REQU.3
36 Unused
210*297(mm) KTE CO., LTD TI-06(R0)

4.3. TERMINAL OUTPUT 03
01 +24V POWER SUPPLY

02 +24V
03 +24V
04 +24V
05 GND POWER SUPPLY
06 GND
07 GND
08 GND
09 Unused
10 Unused
11 Unused
12 Unused
13 Unused
14 Unused
O
15 Unused
U
16 Unused
T
17 Unused
P
18 Unused
U
19 Unused
T
20 Unused
21
PPC NORMAL Contact(A-C) 0
22
3
23
No.1 ACB Close Contact(A-C)
24
25
26
27
28
29
No.1 ACB Open Contact(A-C)
30
31
32
33
34
35
Heavy Load Contact(A-C)
36
210*297(mm) KTE CO., LTD TI-06(R0)

4.4. TERMINAL OUTPUT 04
P(+24V) 01 COM
02 Unused
03 Unused
04 Unused
05 No.1 GEN VOLTAGE Build Up
08 No.1 ENG START
09 No.2 ENG START
10 No.3 ENG START
11 No.1 GEN AUTO LOAD SHIFT
14 No.1 1st ST'BY
15 No.2 1st ST'BY
O
16 No.3 1st ST'BY U
17 No.1 ENG STOP T
18 No.2 ENG STOP P
U
19 No.3 ENG STOP T
20 No.1 2nd ST'BY
21 No.2 2nd ST'BY 0
4
22 No.3 2nd ST'BY
23 No.1 ACB NON CLOSE
26 No.1 ABNORMAL TRIP
29 BIG MOTOR OUTPUT 1
32 LOAD BALANCE ABNORMAL
33 POWER AVAILABLE 1
36 ALARM OUT (System Error)
210*297(mm) KTE CO., LTD TI-06(R0)

5. INPUT / OUTPUT REFERENCE TABLES
PPC I/O TABLE
TYPE : INPUT 00 No. 1/4
TER.NO. SIGNAL NAME SYMBOL

01 ANALOG INPUT 1 (+) 4 - 20mA
02 ANALOG INPUT 1 (-) 4 - 20mA
11 GND
12 GND
13 F.G (Frame Ground)
14 F.G
15 X
I 16 X
N 17 X
P 18 X
U 19 X
T 20 X
00 21 X
22 X
23 X
24 X
25 No.1 GEN AUTO MODE SELECT INP 01.0 143A AUTO
28 No.1 GEN ABNORMAL RESET INP 01.3 3R-128
31 No.1 GEN (ENG. START SW.) INP 01.6 3-106 CS11
34 No.1 GEN (ENG. STOP SW.) INP 02.1 3-105 STOP
210*297(mm) KTE CO., LTD TI-06(R0)

PPC I/O TABLE
TYPE : INPUT 01 No. 2/4

01 No.1 GEN (ACB OPEN SW.) INP 02.4 CS11 OPEN
04 AUTO LOAD SHARING INP 02.7 43-77 AUTO
05 No.1 GEN READY TO START INP 03.0 ENG1 READY
08 No.1 GEN RUN INP 03.3 114X RUN
11 No.1 GEN STOP INP 03.6 105X STOP
14 No.1 GEN ACB CLOSE INP 04.1 CB1 CLOSE
15 No.2 GEN ACB CLOSE INP 04.2 CB2 CLOSE
I 16 No.3 GEN ACB CLOSE INP 04.3 CB3 CLOSE
N 17 GEN. VOLTAGE BUILD UP INP 04.4 84G
P 18 X
U 19 X
T 20 PC RUN PC RUN
01 21 No.1 GEN ACB TRIP (OCR. RPR) INP 05.0 CB1 TRIP
22 No.2 GEN ACB TRIP (OCR. RPR) INP 05.1 CB2 TRIP
23 No.3 GEN ACB TRIP (OCR. RPR) INP 05.2 CB3 TRIP
24 HEAVY LOAD (PWC) INP 05.3 HEAVY LOAD
25 LIGHT LOAD (PWC) INP 05.4 LIGHT LOAD
26 HIGH POWER (PWC) INP 05.5 HIGH LOAD
27 ACB OPEN COMMAND (PWC) INP 05.6 O POWER
28 BUS ABNORMAL (PWC) INP 05.7 BUS ABN
29 ACB NON CLOSE (ASD) INP 06.0 NON CLOSE
30 AUTO SYNCHRO FAIL (ASD) INP 06.1 SYNCH FAIL
31 PREF. TRIP INP 06.2 PREF TRIP
32 BUS NO VOLT INP 06.3 BUS NO VOLT
33 REQU.1 (BIG MOTOR START) INP 06.4
36 X
210*297(mm) KTE CO., LTD TI-06(R0)

PPC I/O TABLE
TYPE : OUTPUT 03 No. 3/4

01 +24V POWER SUPPLY
02 +24V
03 +24V
04 +24V
05 GND POWER SUPPLY
06 GND
07 GND
08 GND
09 X
10 X
11 X
12 X
13 X
14 X
15 X
O 16 X
U 17 X
T
18 X
P
U 19 X
T 20 X
03 21 PPC NORMAL CONTACT (A) OUT 01.0
22 PPC NORMAL CONTACT (C)
23 No.1 ACB CLOSE CONTACT (A) OUT 01.1
24 No.1 ACB CLOSE CONTACT (C)
29 No.1 ACB OPEN CONTACT (A) OUT 01.4
30 No.1 ACB OPEN CONTACT (C)
35 HEAVY LOAD CONTACT (A) OUT 01.7
36 HEAVY LOAD CONTACT (C)
210*297(mm) KTE CO., LTD TI-06(R0)

PPC I/O TABLE
TYPE : OUTPUT 04 No. 4/4

01 COM (P) +24V
02 X
03 X
04 X
05 No.1 GEN VOLTAGE BUILD UP OUT 02.0
08 No.1 ENG START OUT 02.3
11 No.1 GEN AUTO LOAD SHIFT OUT 02.6
14 No.1 1st ST'BY OUT 03.1
15 No.2 1st ST'BY OUT 03.2
O 16 No.3 1st ST'BY OUT 03.3
U 17 No.1 ENG STOP OUT 03.4
T
18 No.2 ENG STOP OUT 03.5
P
U 19 No.3 ENG STOP OUT 03.6
T 20 No.1 2nd ST'BY OUT 03.7
04 21 No.2 2nd ST'BY OUT 04.0
22 No.3 2nd ST'BY OUT 04.1
23 No.1 ACB NON CLOSE OUT 04.2
26 No.1 ABNORMAL TRIP OUT 04.5
29 No.1 BIG MOTOR START OUTPUT OUT 05.0
32 LOAD BALANCE ABNORMAL OUT 05.3
33 POWER AVAILABLE 1 OUT 05.4
36 ALARM OUT (System Error) OUT 05.7
210*297(mm) KTE CO., LTD TI-06(R0)

6. INTERNAL SETTING & ADJUSTING
6.1. INTERNAL SETTING TABLE
Application Comments
C-A Using i8097

JP1 CPU Selection
C-B Using i80C196
C-A Using internal memory

JP2 Memory Selection
C-B Using external memory
C-A Using 27c64

JP3 ROM Selection
C-B Using 27c256
JP4
C-A
JP5 Communication
Method
JP6 Selection
C-B RS - 232c Serial Communication
JP7
1 ON▪ OFF
2 ON▪ OFF
SW8 3 ON▪ OFF
4 ON▪ OFF
5 ON▪ OFF
(Remark) “ ” : Default setting value (Do not intentional modifying after purchasing)
【 VR Setting 】
VRA1 ～ A3 : Volumes for offset adjustment (Do not touch)

VRB1 ～ B1 : Volumes for offset adjustment (Do not touch)
VRC1 ～ C1 : Volumes for analog input rated value adjustment (Do not touch)
VR1 : Volumes for internal power +5V range adjustment (Do not touch)
VR2 : Volumes for internal power +12v range adjustment (Do not touch)
VR3～4 : Volumes for internal power -12V range adjustment (Do not touch)
210*297(mm) KTE CO., LTD TI-06(R0)

6.2. Panel Switch using method
- - - - : 감소
1 2 3
+ + + + : 증가
SW3 (0～9)
SW2 (0～9)
SW1 (0～9)
Using the panel switch attached to the front, we can recognize internal each data setting value and
status.
Using method is same the following.
(The following can be applied to only KT-PPC-A type model)
SW1 SW2 SW3 CONTENT

0 0 0 run : Normal operation
0 X Unused
1 X No.1 Generator power (Kw)
4 X Generator total power (Kw) < ACB close>
1
5 X Internal +5V power setting (VR1)
6 X Internal +12V power setting (VR2)
7 X Internal -12V power setting (VR3,4)
8 X Unused
9 X Unused
0 X Unused
1 X No.1 Generator capacity ratio (%)
4 X Generator total power (%)
2
5 X Unused
6 X Unused
7 X Unused
8 X Unused
9 X Unused
※ X:0 ～ 9
210*297(mm) KTE CO., LTD TI-06(R0)

7. DIAGNOSTIC & TROUBLES AND CORRECTING MEASURES
As soon as you power on this product, it starts self-diagnosis function and show you the result, so it
help you not to perform a failure due to the initial system errors.
When you need to perform self-diagnosis function, just push the 'RESET' button, then it will show you
the diagnosis results. (Note : Do not push 'RESET' button while the system operate). Error messages and
trouble shooting methods of diagnosis results are explained as follows.
No Error Message Probable causes Corrective measures

EEPROM (IC13) Fault EEPROM (IC13) Exchange
EEPr
1
EEPROM Fault
Internal Circuit Fault Circuit check or Exchange
Internal Overvoltage Inspect & Adjust (VR1)
ErrP
2 Power Line Short or Broken Power Line Check
Internal Voltage Fault (+5V)
E P5
EP12
Internal Overvoltage Inspect & Adjust (VR3,4)
E-12
Internal Voltage Fault (-12V)
GEnX Analog Input(AnX) Short or Broken ANx Line Check
6 GEN, No.X (X : 1,2,3) External Power Detector Fault Power Detector Check
Analog Input Fault Internal Circuit Fault Circuit check or Exchange
GEXX Analog Input(AnXX) Short or Broken ANx,x Line Check
7 GEN, No.XX (XX :12,13,23) External Power Detector Fault Power Detector Check
G123 Analog Input(An1,2,3) Short or Broken AN1,2,3 Line Check
8 GEN, NO.1,2,3 External Power Detector Fault Power Detector Check
InXX Internal Input IC Fault Defective IC Exchange
9 Channel No.XX (1～48) Internal Input Line Short or Broken Board check or Exchange
Internal Input Fault Internal Circuit Fault Circuit check or Exchange
ouXX Internal Output IC Fault Defective IC Exchange
10 Channel No.XX (1～40) Internal Output Line Short or Broken Board check or Exchange
Internal Output Fault Internal Circuit Fault Circuit check or Exchange
REMARK : NO6, 7, 8 Analog input Fault

- If the analog input becomes less than 2.4mA, an alarm occurs about 5 seconds later.
210*297(mm) KTE CO., LTD TI-06(R0)

8. EXTERNAL FORM
210*297(mm) KTE CO., LTD TI-06(R0)

9. Product Storage Precautions
1) When heavy dust or metal particles are present in the air, store it by using a cover or a package.
2) Do not store it in such an area that is subject to corrosive gases.
3) Do not sort it in such an area that is subject to direct sunlight.
4) Do not store it in such an area that is subject to ambient temperatures lower than -10℃, higher than
70℃ and relative humidity more than 90% RH.
210*297(mm) KTE CO., LTD TI-06(R0)

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INSTRUCTION MANUAL

Programmable Power Controller

REV DATE REASON MADE CHECKED APPROVED

V1.0E 1994.11. Beginning D.H.Hwang S.W.Jeong J.Y.Chung

V1.1E 2006.11.20. Change of document form D.H.Hwang S.W.Jeong J.Y.Chung

V1.2E 2007.08.17 Add REMARK C.Y.Jeong S.W.Jeong J.Y.Chung

V1.5E 2010.01.20. Add Product Storage Precautions C.Y.Jeong S.W.Jeong J.Y.Chung

Document No. TIR9402-30-D01

210*297(mm) KTE CO., LTD TI-06(R0)

Downloaded from www.Manualslib.com manuals search engine

210*297(mm) KTE CO., LTD TI-06(R0)

Downloaded from www.Manualslib.com manuals search engine

210*297(mm) KTE CO., LTD TI-06(R0)

Downloaded from www.Manualslib.com manuals search engine

1.2. GENERAL SPECIFICATIONS

Power Source DC 24V ±20%

Current Consumption Max 1A / DC 24V

Communication RS-232c serial 1 port

Control system Intel 80c196kc 16Bit microcomputer

CPU Program system Assemble description system

Specification Program memory External 32K bytes(27c256) EPROM

Internal 256bytes RAM

210*297(mm) KTE CO., LTD TI-06(R0)

Downloaded from www.Manualslib.com manuals search engine

2.1. DIAGRAM OF POWER MANAGEMENT CONTROL SYSTEM (FOR SHIP)

210*297(mm) KTE CO., LTD TI-06(R0)

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2.2. DIAGRAM OF POWER MANAGEMENT CONTROL SYSTEM

(WITH INCOMING POWER)

210*297(mm) KTE CO., LTD TI-06(R0)

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3. SYSTEM FLOW CHARTS

3.1. Auto Parallel Running by Heavy Load & Pref. Trip

3.2. Auto Parallel Running Cancellation by Light Load

3.3. Auto Changeover by BUS No Voltage

3.4. Auto Changeover by BUS Abnormal

3.5. Auto Parallel Running by ACB Trip

210*297(mm) KTE CO., LTD TI-06(R0)

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3.1. Auto Parallel Running by Heavy Load & Pref. Trip

210*297(mm) KTE CO., LTD TI-06(R0)

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3.2. Auto Parallel Running Cancellation by Light Load

210*297(mm) KTE CO., LTD TI-06(R0)

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3.3. Auto Changeover by BUS No Voltage

210*297(mm) KTE CO., LTD TI-06(R0)

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3.4. Auto Changeover by BUS Abnormal

210*297(mm) KTE CO., LTD TI-06(R0)

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3.5. Auto Parallel Running by ACB Trip

210*297(mm) KTE CO., LTD TI-06(R0)

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4. INPUT / OUTPUT SPECIFICATIONS

4.1. TERMINAL INPUT 00

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4.2. TERMINAL INPUT 01