Si-Tec Setup and Commissioning Manual

Si-TEC Xtend series
TGC (Total Generation Control) + CGC (Co-Generation Control)

for Reciprocating Engines
Set Up and Commissioning Manual
Copyright 2000 by Dawson Technology Pty Limited. All rights reserved. This document may not be reproduced or distributed to
a third party without prior approval.
Manual No. 549-011 rev A

_________________________
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Dawson Technology Pty Limited

231 Holt Street
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AUSTRALIA
Tel: (07) 38684777 {International: (61)-7-38684777}
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_________________________
July-01/rev A
WARNING
Please read this entire manual and all other publications pertaining to the work to be performed
before installing, operating or servicing this equipment.
Practise all plant and safety instructions and precautions. Failure to follow instructions may result in
personal injury and/or damage to property.
WARNING
The engine, turbine or other type of prime mover must be equipped with an overspeed
(overtemperature, or overpressure, where applicable) shutdown device(s) that operates totally
independently of the prime mover control device(s) to protect against runaway or damage to the
prime mover and to protect against possible personal injury or loss of life, should the mechanical
hydraulic governor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s),
the linkage(s), or the controlled device(s) fail.
In the case of generator sets, an effective monitoring system must be available to prevent damages
by overcurrent, voltage differences or reverse power.
PLEASE NOTE
This manual has attempted to provide instructions on the techniques of electronic governing and the
use of accessories, using examples and data that are believed to be accurate.
However, the examples, data and other information are intended solely as a training aid and should
not be used in any particular application without independent testing and verification by the party
performing the application.
Independent testing and verification are critical in any application, particularly where malfunction of
the equipment may result in personal injury and/or property damage.
For these reasons Dawson Technology provides no warranty of any kind, either expressed or
implied, with respect to the contents of this manual, that the examples and data used are consistent
with industry standard and that they meet the requirements of any particular application.
Dawson Technology disclaims any implied warranties for the manual’s quality, performance,
merchantability or fitness for any particular purpose. Dawson Technology also disclaims all liability
for direct, indirect, incidental or consequential damages that result from any use of the examples,
data or other information in this manual.
IMPORTANT
Correct set points must be entered into the Si-TEC Xtend module for each specific application
prior to starting the engine.
Particular care should be taken with regard to cable shielding and power supply connections to
ensure the equipment meets all requirements specified by Dawson Technology concerning EMI.
CONTENTS
Subject Heading Page
1 Configuring the Module 1

1.1 Introduction 1
1.2 Terminology 1
1.3 Navigating the Menu System and Tips 1
2 Si-TEC Xtend Menu Preset Item Description for Reciprocating Engine

Driven Generators 3
2.1 Module Identification – Information Only 3
2.2 System Diagnostics and Functional Tests – main menu 3
Alarm Status – sub menu 3
Trip Cause – Information – sub menu 3
Module to Module – Communications – sub menu 3
Display I/O States – sub menu 3
Force Outputs Test – sub menu 3
Actuator Test – sub menu 3
2.3 Instrument Data – Control Parameter Information Only – main menu 4
Info / Synchronising – sub menu 4
Info / Alternator – sub menu 4
Info / Actuator – sub menu 4
Info / Peak Hold – sub menu 4
2.4 Configure Module – main menu 5
VT and CT Ratio – sub menu 5
Module Setup – sub menu 5
2.5 Speed Governor – Control Function – main menu 6
Speed Control – Set Point Parameters – sub menu 6
Start Sequence – Actuator – sub menu 6
PID Adjustments – Speed Loop Response - sub menu 6
Performance Enhanced – PID Adjustments – sub menu 6
Multi Point PIDs – Island Mode ‘On Load’ – sub menu 7
2.6 Generator / Alternator – Control Function – main menu 8
Frequency (Hz) – Set Point Parameters – sub menu 8
Synchronising – Set Point Parameters – sub menu 8
Voltage / AVR Control – sub menu 8
KWatt Control – Set Point Parameters - sub menu 9
KVAr / Power Factor – Set Point Parameters – sub menu 9
2.7 Manual Mode Set Point Parameters 10
2.8 Logic and Analog I/O - Configure – Set Parameters - main menu 11
Logic Inputs – Allocate a Task to an Input – sub menu 11
Logic Outputs – Allocate a Function to a Relay – sub menu 11
kWh / kVArh Meter – Pulsed Output – sub menu 11
Analog Inputs – Allocate to Input – sub menu 12
Analog Outputs – Assign Data Type – sub menu 12
2.9 Relay Outputs / Alarms – Switch Set Points – main menu 13
Speed (RPM) – Switch Set Points 13
Volt / Frequency – Switch Set Points 13
KWatt – Switch Set Points 13
KVAr – Switch Set Points 14
Group Switch Points – ‘together’ to form Combined Alarms 14
Miscellaneous – Switch Point Limits 14
Paralleled to Mains Switch Point 14
Vector Disturbance – Switch Point Limits 14
3 Detailed Description of the Menu Items 15

3.1 Module Identification – Information Only 15
3.2 System Diagnostics and Functional Tests 15
3.3 Instrument Data 15
3.4 Configure Module – main menu 16
VT and CT Ratio – sub menu 16
Module Setup – sub menu 16
3.5 Speed Governor – Control Function – main menu 18
Speed Control – Set Point Parameters – sub menu 18
Start Sequence – Actuator – sub menu 19
PID adjustments – Speed Loop Response – sub menu 20
Performance Enhanced – PID adjustments – sub menu 22
Multi Point On Load PID – Island Mode – sub menu 22
3.6 Generator / Alternator – Control Function – main menu 24
Frequency Set Point Parameters – sub menu 24
Synchronising Set Point Parameters – sub menu 24
Voltage / AVR Control – sub menu 25
KWatt Control – Set Point Parameters – sub menu 27
KVAr / Power Factor Control – sub menu 29
3.7 Manual Mode Set Point Parameters 31
3.8 Logic and Analog I/O – Configure – Set Parameters 32
Logic Inputs – Allocate a Task to an Input – sub menu 32
Relay Outputs – Allocate a Function to a Relay – sub menu 35
KWh / KVAr Meter – Pulsed Output – sub menu 36
Analog Inputs – Allocate to Input – sub menu 36
Analog Outputs – Assign Data Type – sub menu 38
3.9 Relay Outputs / Alarms – Switch Set Points – sub menu 40
Speed (RPM) – Switch Set Points 40
Volts / Frequency – Switch Set Points 40
KWatt – Switch Set Points 41
KVAr – Switch Set Points 41
Group Switch Points – ‘together’ to form Combined Alarms 41
Miscellaneous Switch Point Limits 41
Paralleled to Mains Switch Point 41
Vector Disturbance – Switch Point Limits 41
4 Control Notes 42
4.1 Logic Inputs 42
4.2 Fixed Logic Inputs 43
4.3 Combined Alarms 44
5 PID Controls 46
5.1 Speed Control – Multiple Dynamics 46
5.2 P.I.D. Definitions 46
5.3 Rated Proportional / Rated Integral / Rated Derivative 47
5.4 Do Fast Response when out of % band / Fast Resp.Prop. / Fast Resp. Int. 47
5.5 Multiple On Load PIDs 48
5.6 Menu Preset Items for additional PID functions 50
6 Operation and Service Information 51

6.1 Actuator – MPU – Linkage Adjustments 51
6.2 Analog Biasing for AVR Voltage Trimming 53
6.3 AVR Connections for Analog Voltage Trimming 54
6.4 Si-TEC Xtend CGC & GSM Vector Disturbance Relay 56
7 Form STC – 010 rev A 57

7.1 Generator Setup 57
7.2 Generator Synchronising and Parallelling 61
7.3 GSM Master Module 62
8 Fault Finding 65
9 Si-TEC Xtend Communication Addresses accessed from RS232

Communications Port and User RS485 Port 68
9.1 Si-TEC Xtend module Address Range 68
9.2 Generator Module Address (Offset) Data Reference 69
9.3 Generator State Table 1 (Address Offset 1) 70
9.4 Generator Status and Alarms Table (Logic Items) 71
9.5 Generator Logic Input 1 & 2 Tables 71
1 CONFIGURING THE MODULE
This manual details the configuration and description of the Si-TEC Xtend control software menu
items, and should be used as a reference during the commissioning of the Si-TEC Xtend control
system. It is assumed that the user has also read and understood the contents of the Si-TEC Xtend
“Design and Installation” Manual (ref no. 549-010a).
1.1 Introduction
The Si-TEC Xtend control module is a pre-programmed processor operating with a combination of
designated inputs and outputs for engine-generator control. In addition to the "standard" control
inputs and outputs for speed governing, synchronising, load control, etc., a number of inputs and
outputs are provided for user application selection. The Si-TEC Xtend control module is supplied
with default settings for several input and output functions. These settings may differ for each
application requirement and therefore it may be necessary to verify all preset values prior to the
initial starting of the engine-generator.
1.2 Terminology
The following is a description of terms used within this document:
Analog Input: RTD, 0-5V, or 4-20mA input signals.
Analog Output: 4-20mA output for driving external metering etc.
Logic Input: a switched input voltage (nominally 24Vdc).
Relay Output: voltage free contacts for providing output control.
High Input: when 24Vdc is applied to a logic input.
Low Input: when the logic input has 0Vdc applied.
Preset Value: default set point value of an internal control function, which is adjustable
via the menu system for final application settings.
Generator CB: the respective generator circuit breaker.
Mains CB: the circuit breaker(s) connecting the main bus to the incoming supply,
supply grid or utility.
Vector Disturbance: the rate of change of phase angle for detecting loss of the supply authority
(mains) grid.
1.3 Navigating the Menu System and Tips
i) A three tier menu system is used. The ^ and v keys and the "Select Menu" key will
scroll you through all the menu items.
ii) Push the "Select Menu” key to enter within a "Main Menu" or a "Sub Menu".
iii) At the end of a “Sub Menu” group a "End of Sub Menu" text will appear. The ^ and v
keys will continue to operate within the "Sub Menu"
iv) To exit a "Sub Menu" press the "Select Menu" key, which will return you to the "Sub
Menu" header.
v) Pressing the v key at the last “Sub Menu” header will move to the next “Main Menu”
header.
1
vi) To edit the preset values it is necessary for the correct user “Access” PIN to be
entered, followed by pressing the "Reset" key. The factory shipped “Access” PIN is “3”.
vii) The factory “Access” PIN of “3” will be restored by entering “7654321” for the PIN. This
provides access in case the user forgets the PIN, and also advises the supervisor of
the change.
viii) A shortcut key is available to provide direct access to a menu item. This is possible by
pressing the "Go To Menu #" key followed by the menu item number. The menu item
number for any display screen is displayed after pressing the “Help” key. Pressing the
“Help” key a second time will exit the “Help” screen.
ix) Should the screen “Text” flash, this would indicate that a menu item value has been
altered without being saved.
x) Pressing the "Reset" key at the displayed "Active Alarm" will stop the “Back Light” from
flashing. The Shortcut "Alarm" key may be used for quick navigation of the menu.
xi) It should be noted that the "Course" adjust keys (i.e. the “large” + or – keys) do not
operate several preset menu items.
xii) Should a set point be beyond the range limit, the "Back Light" will commence flashing.
xiii) The “Fine” adjust keys (i.e. the “small” + or – keys) should be used when selecting text
items within the sub-menus, or during PID control dynamics fine-tuning.
The next section provides a listing (in order of display) of the Si-TEC Xtend menu items. This listing
also includes the menu tier, the menu item for direct accessing, the minimum value and the
maximum value. A detailed description of the menu items will follow this listing (section 3).
2
2 Si-TEC Xtend Menu Preset Items for Reciprocating Engine-Generators
Sections 2.1 & 2.2
Menu Description Minimum Maximum Factory
Item # Setting
Module Identification ‘Information Only’ – Main
Menu
System Diagnostics & Functional Tests – Main
Menu
Alarm Status (Sub Menu)
010 Active Alarms – Listed
011 Alarm History – Listed
012 Variable Errors – Listed
Trip Cause – Information (Sub Menu)

017 CB Trip Cause - + previous 4 trips
018 Time Since Gen. CB Trip d:hh:mm:ss
019 Time Since Vector Alarm d:hh:mm:ss
021 Time Since CPU Reset d:hh:mm:ss
Module to Module – Communications (Sub Menu)

Master 0 - Group # - time out - Control Mode– kW– kVAr
027 Listing of all Si-TEC Xtend modules inter-communicating
028 Diagnostic Data of Si-TEC RS485 inter-comms
Display I/O States (Sub Menu)

037 Logic Inputs -16x 1-16 :16x CAN : 0=Low :1=High
038 Logic Outputs - 1x CB : 8x Relay : 8x CAN
040 Analog Input 1 : RTD
041 Analog Input 2 : 4-20mA
044 Analog Output 1 : 4-20mA
047 Voltage Bias to AVR
048 Gen : Volt - Current
049 Bus : Volt
050 MPU 1 and MPU 2 – signals
Force Outputs Test (Sub Menu)

061 Toggle Relay (Use 'BUMP' To Toggle) 1 16
062 4-20mA Output AO-1 Forced to 0 22
065 4-20mA Output AO-4 On CANBUS Forced to 0 22
068 AVR Bias Output - Forced to :-
Actuator Test (Sub Menu)

081 Set Actuator Position 1 -5 105
082 Set Actuator Position 2 -5 105
083 Auto Toggle Actuator - Test No Yes No
3
Section 2.3
Item # Set
Instrument Data – Control Parameters

‘Information Only’ – Main Menu
Info / Synchronising (Sub Menu)

094 Bus and Gen Voltage and Hz and Phase Angle
095 Bus and Gen Voltages 3 Phase
Info / Alternator (Sub Menu)

100 Generator 3 Phase V, A, kW, kVAr, PF, Hz
101 Generator A Phase V, A, kW, kVAr, PF, Hz
102 Generator B Phase V, A, kW, kVAr, PF, Hz
103 Generator C Phase V, A, kW, kVAr, PF, Hz
104 kWatt and kVAR Phases A, B, C
Info / Actuator (Sub Menu)

108 Desired%, Actual%, Actuator Current and Volts
Info / Peak Hold (Sub Menu)

113 Peak: RPM, kWatt, kVAr
114 Peak: Currents Phases A, B, C
115 Peak: Vector angle shift
4
Section 2.4
Item # Set
Configure ‘Module’ For Your Application – Main

Menu
VT and CT Ratio (Sub Menu)

120 Voltage range at GEN Input of Module p/n 0 1 1
121 VT Ratio(GEN to GEN Input of Module) 0.50 655.00 1.00
122 Voltage range at BUS Input of Module p/n 0 1 1
123 VT Ratio(GEN to BUS Input of Module) 0.50 655.00 1.00
124 Gen. CT Max Output 0=(1A) OR 1=(5A) 0 1 1
125 CT Primary Current CT Ratio 5 32500 240:1
Module Setup (Sub Menu)

131 Module Number 1 23 1
133 Pin Number for User Access Code [factory shipped at 3] 0 999999 3
134 Set Master Priority 0 for unit#0, 1=#23 0 1 0
135 RS232 baud rate 2400 to 38400 baud [refer table] 0 4 2 [9600]
136 RS232 Word Endian 0 = big 1 = little 0 1 0
137 User RS485 Address 1 247 200
138 User RS485 Mode 0 = ASCII 1 = RTU 0 1 0
139 User RS485 Response Delay [in mSec] 2 100 3
140 User RS485 W.Endian 0 = big 1 = little 0 1 0
141 Alarm On Stretch Time for Si-TEC LAN 1 600 10
5
Section 2.5
Item # Set
Speed Governor – Control Function Set Point
Parameters – Main Menu
Speed Control - Set Point Parameters (Sub Menu)
177 Backup MPU Connected to MPU Input No.2 No Yes No
178 Number of 'TEETH' On MPU Speed Sense Gear 1 500 108
179 Gear Reduction Ratio Main Shaft/MPU Shaft 0.1000 20.0000 1.0000
180 MPU Failure Shutdown Bypass on Startup No Yes No
181 IDLE Speed RPM 100 20000 750
182 IDLE Hold Time Seconds 0.0 3600.0 1.0
183 RAMP To Rated Speed at%/sec of Rated RPM 0.01 99.99 15.0
184 Fast RAMP to Rated at%/sec of Rated RPM 0.01 99.99 30.0
185 RATED Speed RPM (operating speed) 200 20000 1500
186 Warm Up Time at RATED RPM (minutes) 0.0 1200.0 1.0
187 Engine 'COOL DOWN SPEED' RPM 1 20000 1500
188 Engine 'COOL DOWN Time' (minutes) 0.0 2000.0 0.2
189 'OVER-SPEED TEST' Maximum RPM 1 22000 1800
Start Sequence – Actuator (Sub Menu)

198 Start FUEL LIMITING Actuator Position % 0.1 100.0 35.0
199 INCREASE Actuator LIMIT Position %/sec 0.1 100.0 10.0
200 Max. Act. Position when Starting 0.0 100.0 100.0
201 Max. Act. Pos. when On-line in % 0.0 100.0 100.0
202 Use 'Start Limit' on all 'crank attempts No Yes Yes
203 'Gas Purging Crank Time' First Crank 0.0 60.0 Gas Ver.
204 Number of Purge Cranks 1 10 Gas Ver.
205 Actuator Position During Purge Crank 0 100 Gas Ver.
206 Crank 'CUT-OUT RPM' 1 20000 350
207 Crank 'ON TIME' Seconds 0.1 60.0 10.0
208 Crank 'OFF TIME' Seconds 0.1 60.0 5.0
209 Number of 'CRANK ATTEMPTS' 0 10 3
210 Max. 'PRE-HEAT TIME' Pre Crank (IF used) 0.0 60.0 15.0
211 PRE-HEAT between Crank Attempts [Y/N] No Yes No
212 Manual Start Time out in Seconds 0.1 1000.0 130.0
PID Adj. - Speed Loop Response (Sub Menu)

232 PROPORTIONAL (Gain) at IDLE RPM 1 99 40
233 INTEGRAL at IDLE RPM 1 99 48
234 DERIVATIVE at IDLE RPM 0 99 15
235 PROPORTIONAL (Gain) at RATED RPM 1 99 41
236 INTEGRAL at RATED RPM 1 99 60
237 DERIVATIVE at RATED RPM 0 99 5
238 PROPORTIONAL (Gain) Paralleled to grid 1 99 30
239 INTEGRAL Paralleled to grid 1 99 50
240 DERIVATIVE Paralleled to grid 0 99 5
242 Actuator Disturbance (BUMP MAGNITUDE) 0.0 100.0 5.0
243 Actuator Disturbance (BUMP DURATION) 0.0 25.0 0.5
244 Disturbance DELAY after 'pressing Bump' 0.0 60.0 1.0
Performance Enhanced- PID Adj. (Sub Menu)

251 Do FAST RESPONSE when out of % Band 0.0 50.0 1.0
252 Fast Response PROP.Gain Multiplier 1.0 15.0 2.0
253 Fast Response INTEGRAL Multiplier 1.0 25.0 2.5
265 Speed PI Multiplier Hold Off Time 0.0 60.0 3.0
6
254 Do Rapid Response on GEN BREAKER Trip No Yes Yes
255 Do Also on MAINS BREAKER Trip No Yes No
258 Use Torsional Filter (Y, N) for Control No Yes Yes
Multi Point PIDs - Island Mode ‘On Load’ (Sub Menu)

271 Enable MULTI point On-Load speed PIDs No Yes No
272 PROPORTIONAL (Gain) At 100% kWatt Load 1 99 55
273 INTEGRAL At 100% Load 1 99 50
274 DERIVATIVE At 100% Load 0 99 40
275 % Load of Rated kW for Mid Point PIDs 0.0 99.0 40.0
276 PROPORTIONAL (Gain) Mid Point kWatt Load 1 99 50
277 INTREGRAL Mid Point kWatt Load 1 99 50
278 DERIVATIVE Mid Point kWatt Load 0 99 35
7
Section 2.6
Item # Set
Generator / Alternator – Control Function Set

Point Parameters - Main Menu
Frequency (Hz) - Set Point Parameters (Sub Menu)

287 Rated FREQUENCY (Hz) (Must = RATED Speed) 45.0 67.0 50.0
288 Follow Bus Freq. To Min Limit(%of Rated) 75.0 100.0 94.0
289 Follow Bus Freq. To Max Limit(%of Rated) 100.0 125.0 105.0
Synchronising - Set Point Parameters (Sub Menu)

301 PROPORTIONAL (Gain) Synchroniser Control 1 99 40
302 INTEGRAL Synchroniser Control 0 99 15
303 Max. Hz BIAS to Correct Phase Error 0.1 2.5 1.5
304 Hz HIGHER Sync ONLY (Synchroscope CW) 0 1 0
305 Max. SLIP FREQUENCY (Must be < To Close) 0.05 2.00 0.20
306 PHASE ANGLE Window (Must be < To Close) 0.1 15.0 10.0
307 PHASE Matching Offset COMPENSATION -15.0 15.0 0.0
308 No SYNC if BUS Hz Below? (% of Rated) 75.0 100.0 96.0
309 No SYNC if BUS Hz Above? (% of Rated) 100.0 125.0 104.0
310 SYNC exit time 0.0 1.0 0.1
312 VOLTAGE MATCH Window (Must be < To Close) in% 0.0 50.0 0.8
313 VOLTAGE Matching Offset COMPENSATION in% -2.0 5.0 0.0
314 NO SYNC if BUS VOLTS Below (% of Rated) 50.0 100.0 90.0
315 NO SYNC if BUS VOLTS Above (% of Rated) 100.0 150.0 110.0
Voltage / AVR Control – Set Point Parameters (Sub

Menu)
326 PROPORTIONAL (Gain) Voltage Control 1 99 45
327 INTEGRAL Voltage Control 1 99 60
328 AVR Control Method 0 = Relay,1 = Analog 0 1 1
329 Gen. RATED VOLTAGE ph-ph ph-n 50 650000 240
330 Voltage DEAD BAND % of Rated Voltage 0 20 0.0
331 Voltage Control Delay Before Active 0.0 100.0 0.5
332 Follow BUS Volts To Min Limit(% Rated V) 50.0 100,0 80.0
333 Follow BUS Volts To Max Limit(% Rated V) 100.0 150.0 120.0
334 Min.AVR Bias Voltage From Si-TEC Xtend module -8.4 8.4 -1.5
335 Max.AVR Bias Voltage From Si-TEC Xtend module -8.4 8.4 2.0
336 AVR Bias Disturbance BUMP Magnitude(test) -8.4 8.4 0.7
337 AVR Bias Disturbance BUMP Duration(test) 0.0 100.0 0.0
338 AVR Bump Delay Time after 'Pressing Bump' 0.0 60.0 0.0
8
Item # Set
kWatt Control - Set Point Parameters (Sub Menu)

346 PROPORTIONAL (Gain) kWatt Control 1 99 25
347 INTEGRAL kWatt Control 1 99 55
348 kWatt DEAD BAND % of Rated kWatt 0.0 30.0 0.0
349 RATED kWatt (Load) of Generator Set 1 32750 400
350 Re-Rated kWatt of Generator Set 1 32750 10
351 Grid Paralleled kWatt Set Point 1 32750 10
352 Jump to Min. kWatt when Closing Gen CB 0 32750 2
355 Coming OFF LINE Open GEN CB at % of Rated 0.1 500 5.0
356 Coming OFF LINE Open GEN CB Timeout (secs) 0.1 999.9 20.0
357 BASE LOAD Mode (1) kWatt Set-point 1 32750 10
358 BASE LOAD Mode (2) kWatt Set-point 1 32750 10
359 Load (ON) Ramp Rate at %/sec of Rated kW 0.1 100.0 5.0
360 Load (OFF) Ramp Rate at %/sec of Rated kW 0.1 100.0 5.0
361 Fast Load (ON) Ramp at %/sec of Rated kW 0.1 200.0 15.0
362 Fast Load (OFF) Ramp at %/sec of Rated kW 0.1 200.0 15.0
363 Enter APROX Actuator Position at 'NO LOAD' 0.1 100.0 30.0
364 Enter APROX Actuator Position at Max LOAD 0.1 100.0 97.0
365 Minimum Import kWatt When CLOSED to GRID -600000 600000 0
366 Import kWatt (1) When CLOSED to GRID -600000 600000 0
367 Import kWatt (2) When CLOSED to GRID -600000 600000 0
kVAr / PF Control – Set Point Parameters (Sub Menu)

381 PROPORTIONAL (Gain) kVAr/ PF Control 1 99 50
382 INTEGRAL kVAr/ PF Control 1 99 50
383 kVAr Dead Band in % of Rated kVAr 0 30 0.0
384 RATED Power Factor of Generator Set 0.50 1.00 0.80
385 Paralleled to GRID PF Set-Point 0.50 -0.70 0.85
386 Paralleled to GRID kVAr Set-Point -600000 600000 10
387 Leading kVAr Rating 0 600000 5
388 BASE LOAD Mode (1) PF Set-Point 0.50 -0.70 0.85
389 BASE LOAD Mode (2) PF Set-Point 0.50 -0.70 0.80
390 Maximun On-Time for AVR/MOP Driver Relay 0.1 4.0 3.9
391 kVAr DELAY Band in % of Rated 0.0 40.0 0.0
392 kVAr Delay Band Correction Delay 0.0 100.0 0.0
393 kVAr or PF (Grid) Control 0=kVAr 1=PF 0 1 1
9
Section 2.7
Item # Set
Manual Mode - Set Point Parameters
401 Manual Mode Speed DROOP(see next menu) 0.0 25.0 4.0
402 Select droop mode 0=kW or 1=actuator 0 1 0
403 In manual mode what is Desired Min. RPM 30 20000 900
404 In manual mode what is Desired Max. RPM 30 20000 1800
405 Manual Adjust Rate RPM per Second 0.01 200.00 6.00
406 AVR BIAS Voltage starting in manual -8.4 8.4 0.01
407 AVR BIAS Voltage ramp rate Vdc/sec 0.01 1.00 0.05
10
Section 2.8
Item # Set
Logic and Analog I/O – ‘Configure’ ‘Set

Parameters’ – Main Menu
Logic Inputs - Allocate a Task to an Input (Sub Menu)

417 Enable Control via RS485 Comms Select On 17 On
418 Remote Fault Reset Select Off 17 Off
419 Rated Speed Select On 17 On
420 Over Speed Test Select Off 17 Off
421 Fast Rate Select On 17 Off
422 Sequence Hold Select Off 17 Off
423 Pre-heat complete (Pre Crank) Select On 17 On
424 Synchronise Inhibit Select On 17 Off
425 Enable Load Share Select On 17 On
426 kWatt De-Rate Select On 17 Off
427 Base Load Mode (1) Select On 17 Off
428 Base Load Mode (2) Select On 17 Off
429 Gen. Group 1 to 4 1st Bit Select (optional function) On 17 Off
430 Gen. Group 1 to 4 2nd Bit Select (optional function) On 17 Off
431 Main Bus, Re-Sync to GRID Select (CGC only) Off 17 Off
432 Enable Min. Import Select (CGC only) On 17 Off
433 Sum Import Sensors Select (CGC only) On 17 Off
434 Manual Speed Increase Select Off 17 Off
435 Manual Speed Decrease Select Off 17 Off
436 Manual Volts Increase Select Off 17 Off
437 Manual Volts Decrease Select Off 17 Off
438 Auto Select Off 17 On
Logic Outputs - Allocate a Function to a Relay (Sub

Menu)
451 Relay Output RL-1 Select a Function 0 34 Fuel Sol.
452 Relay Output RL-2 Select a Function 0 34 Crank eng
453 Relay Output RL-3 Select a Function 0 34 Not Used
454 Relay Output RL-4 Select a Function 0 34 Run Spd.
455 Relay Output RL-5 Select a Function 0 34 CB Trip
456 Relay Output RL-6 Select a Function 0 34 Rev. kW
kWh / kVArh Meter - Pulsed Output (Sub Menu)

481 kWatt Hour per Pulse 1 10000 1000
482 kWatt Hour pulse on Time 0.1 5.0 1.0
483 kVAr Hour per Pulse 1 10000 1000
484 kVAr Hour Pulse on Time 0.1 5.0 1.0
11
Item # Set
Analog Inputs - Allocate to Input (Sub Menu)

491 High Modbus Ref. Value 100 65535 20000
492 Temperature (RTD) (AI-4) Source 0 4 AI-4
493 RTD AI-4 Zero Offset Comp -25 25 0
497 kWatt CONTROL Allocate To a Source 0 7 EEPROM
498 kWatt CONTROL kW @ Min Reference 0 32766 0
499 kWatt CONTROL kW @ Max Reference 0 32766 400
500 kWatt LIMIT Allocate To a Source 0 7 EEPROM
501 kWatt LIMIT kW @ Min Reference 0 32766 0
502 kWatt LIMIT kW @ Max Reference 0 32766 400
503 kVAr CONTROL (Grid) Allocate To a Source 0 7 EEPROM
504 kVAr CONTROL (Grid) kVAr @ Min Reference -32766 32766 0
505 kVAr CONTROL (Grid) kVAr @ Max Reference -32766 32766 400
506 PF CONTROL (Grid) Allocate To a Source 0 7 EEPROM
507 PF CONTROL (Grid) PF @ Min Reference -0.5000 0.5000 -0.50
508 PF CONTROL (Grid) PF @ Max Reference -0.5000 0.5000 0.50
509 Warm Up Speed Allocate To a Source 0 7 EEPROM
510 Warm Up Speed RPM @ Min Reference 0 20000 0
511 Warm Up Speed RPM @ Max Reference 0 20000 1600
512 1st Import kW Sensor Allocate To a Source 0 7 EEPROM
513 1st Import kW Sensor kW @ Min Reference -32766 32766 0
514 1st Import kW Sensor kW @ Max Reference -32766 32766 1000
515 2nd Import kW Sensor Allocate To a Source 0 7 EEPROM
516 2nd Import kW Sensor kW @ Min Reference -32766 32766 0
517 2nd Import kW Sensor kW @ Max Reference -32766 32766 1000
518 Min Import kW Setpoint Allocate To a Source 0 7 EEPROM
519 Min Import kW Setpoint kW @ Min Reference -32766 32766 0
520 Min Import kW Setpoint kW @ Max Reference -32766 32766 1000
Analog Outputs - Assign Data Type (Sub Menu)

551 Analog Output AO-1 Assign Data Type 0 8 Gen kW
552 Analog Output AO-1 4mA = -600000 600000 0
553 Analog Output AO-1 20mA = - 600000 600000 500
554 Analog Output AO-2 Assign Data Type 0 8 Gen kVAr
557 Analog Output AO-3 Assign Data Type 0 8 Gen PF
12
Section 2.9
Item # Set
Relay Outputs / Alarms – Switch Set Points -

Main Menu
Speed (RPM) – Switch Set Points (Sub Menu)

592 Engine 'RUNNING' Indication RPM 1 22000 1420
593 Engine 'RUNNING' Indication 'Delay' 0.0 360.0 1.0
594 Speed Switch No1 Close at RPM 1 22000 1475
595 Speed Switch No1 Delay before Action 0.0 360.0 3.0
596 Speed Switch No2 Close at RPM 1 22000 1525
597 Speed Switch No2 Delay before Action 0.0 360.0 1.0
598 Speed Deviation From Set-Point (Alarm) 1 5000 500
599 Speed Deviation Delay before Action 0.0 360.0 5.0
600 Speed Deviation Trip Gen CB [D/E/T] 0 2 1 - [Enab.]
Volts / Frequency – Switch Set Points (Sub Menu)

606 GEN Voltage - LOW in %of Rated Voltage 40.0 100.0 95.0
607 GEN Voltage - LOW Delay before Action 0.0 360.0 3.0
608 GEN Voltage - LOW Trip Gen CB [D/E/T] 0 2 1- [Enab.]
609 GEN Voltage - HIGH in %of Rated Voltage 100.0 150.0 105.0
610 GEN Voltage - HIGH Delay before Action 0.0 360.0 3.0
611 GEN Voltage - HIGH Trip Gen CB [D/E/T] 0 2 1- [Enab.]
612 Freq. - LOW (GEN) in % of Rated Freq. 75.0 100.0 97.8
613 Freq. - LOW (GEN) Delay before Action 0.1 360.0 2.2
614 Freq. - LOW (GEN) Trip Gen CB [D/E/T] 0 2 1- [Enab.]
615 Freq. - HIGH (GEN) at % of Rated 100.0 150.0 102.5
616 Freq. - HIGH (GEN) Delay before Action 0.1 360.0 1.0
617 Freq. - HIGH (GEN) Trip Gen CB [D/E/T] 0 2 1- [Enab.]
kWatt – Switch Set Points (Sub Menu)

626 kWatt Reverse Power in % of Rated kWatt 0.1 100.0 7.6
627 kWatt Reverse Power Delay before Action 0.0 360.0 4.0
628 kWatt Reverse Power Trip Gen CB [D/E/T] 0 2 1- [Enab.]
629 kWatt - HIGH in % of Rated kWatt 0.1 250.0 95.0
630 kWatt - HIGH Delay before Action 0.0 360.0 0.3
631 kWatt - HIGH Trip Gen CB [D/E/T] 0 2 1- [Enab.]
632 kW 3Phase Unbalance in % of Rated kWatt 0.1 100.0 30.0
633 kW 3Phase Unbalance Delay before Action 0.0 360.0 4.2
634 kW 3Phase Unbalance Trip Gen CB [D/E/T] 0 2 1- [Enab.]
635 kWatt Switch No1 ON in % of Rated kWatt 0.1 127.0 80.0
636 kWatt Switch No1 ON Delay before Action (sec) 0.0 360.0 10.0
637 kWatt Switch No1 OFF in % of Rated kWatt 0.1 127.0 60.0
638 kWatt Switch No1 OFF Delay before Action (min) 0.0 360.0 0.5
639 kWatt Switch No2 ON in % of Rated kWatt 0.1 127.0 95.0
640 kWatt Switch No2 ON Delay in Seconds (sec) 0.0 360.0 0.5
641 kWatt Switch No2 OFF in % of Rated kWatt 0.1 127.0 85.0
642 kWatt Switch No2 Off Delay before Action (min) 0.0 360.0 5.0
13
Item # Set
kVAr – Switch Set Points (Sub Menu)

651 kVAr - High in % of Rated kVAr 0.1 200.0 120.0
652 kVAr - High Delay before Action 0.0 360.0 3.0
653 kVAr - High Trip Gen CB [D/E/T] 0 2 1- [Enab.]
654 Reverse kVAr/Lead PF in % of Rated Leading kVAr 0.1 200.0 120.0
655 Reverse kVAr/Lead PF Delay before Action 0.0 360.0 3.0
656 Reverse kVAr/Lead PF Trip Gen CB [D/E/T] 0 2 0- [Disb.]
Group Switch Points - 'together' to Form Combined

Alarms (Sub Menu)
681 Latched Comb. Alarm No 1 - Bit Count Value 0 2147483647 0
682 Latched Comb. Alarm No 2 - Bit Count Value 0 2147483647 0
683 Combined Alarm No 1 - Bit Count Value 0 2147483647 0
684 Combined Alarm No 2 - Bit Count Value 0 2147483647 0
Miscellaneous – Switch Point Limits (Sub Menu)

691 Fail to Synchronise Delay before Action [if 0 is disabled] 0.0 360.0 0.0
692 DC Supply Volt Low 18.0 Vdc Suggested 12.0 30.0 18.0
693 DC Supply Volt Low Delay before Action 0.0 360.0 0.2
Paralleled to Mains Switch Point (Sub Menu)
Vector Disturbance – Switch Point Limits (Sub Menu)

711 Loss of Three Phase Angle Shift [in deg] 0.1 100.0 5.0
712 Loss of Three Phase Trip Gen CB [D/E/T] 0 2 1- [Enab.]
713 Phase Unbalanced in Percent 0.1 100.0 30.0
714 Phase Unbalanced Delay before Action 0.01 3.00 0.20
715 Phase Unbalanced Trip Gen CB [D/E/T] 0 2 1- [Enab.]
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3 DETAILED DESCRIPTION OF THE MENU ITEMS
3.1 Module Identification – Information Only – Main Menu
3.2 System Diagnostics and Functional Tests – Main Menu
3.3 Instrument Data – Control Parameters ‘Information Only’ – Main Menu
Info / Synchronising – Sub Menu

Bus and Gen – Voltage, Hz, and Phase Angle
Bus and Gen – Voltages 3 Phase
Info / Alternator – Sub Menu

Generator 3 Phase V, A, kW, kVAr, PF, Hz
Generator A Phase V, A, kW, kVAr, PF, Hz
Generator B Phase V, A, kW, kVAr, PF, Hz
Generator C Phase V, A, kW, kVAr, PF, Hz
KWatt and kVAr Phases A, B, C
Info / Actuator – Sub Menu

Desired %, Actual %, Actuator Current and Volts
Info / Peak Hold – Sub Menu

Peak: RPM, kWatt, kVAr
Peak: Currents Phases A, B, C
Peak: Vector Angle Shift
15
3.4 Configure Module – Main Menu
VT and CT Ratio – Sub Menu
Voltage range at GEN Input of Module ph/n menu 120

Sets the input voltage at the generator voltage sensing terminals (term 104 to 107).
Set to “0” for 63.5 Vac Ph/N (typically from high voltage PTs) or “1” for 240 Vac for direct voltage
input (415 Volts L-L). For 120 Vac Ph/N systems select “1” for the 240 Vac sensing range.
Voltage Ratio (Gen to Gen) input of Module menu 121

Sets the ratio of the generator output voltage to the sensed generator input voltage (term 104 to
107). Where Potential transformers are not used set this value to 1.00. For 11,000 Vac to 110 Vac
PTs set value at 100.00 (ie. 100.00 to 1 ratio). The use of decimal points can provide compensation
for any PT errors.
Voltage range at BUS Input of Module ph/n menu 122

Sets the input voltage at the main bus voltage sensing terminals (term 100 to 103).
Set to “0” for 63.5 Vac Ph/N (typically from high voltage PTs) or “1” for 240 Vac for direct voltage
input (415 Volts L-L). For 120 Vac Ph/N systems select “1” for the 240 Vac sensing range.
Voltage Ratio (Gen to Bus) input of Module menu 123

Sets the ratio of the generator output voltage to the sensed bus voltage (term 100 to 103). Where
Potential transformers are not used and the bus voltage sensing is the same as the generator
voltage set this value to 1.00. For 11,000 Vac to 110 Vac PTs set value at 100.00 (ie. 100.00 to 1
ratio). The use of decimal points can provide compensation for any PT errors.
This menu item is expressed as “Gen to Bus” ratio, allowing for generators operating at 415 Vac
Ph/Ph to synchronise with a 11kVac Ph/Ph bus. For this case, the generator sensing inputs are 415
Vac and the Bus sensing inputs are 110 Vac Ph/Ph (100.00 to 1 primary/secondary ratio). The set
ratio would include for both main transformer ratio and the PT ratio. The set ratio in this instance
would be 415 / 110 = 3.77.
Gen. CT Max Output 0=(1A) or 1=(5A) menu 124

Sets the module to the secondary CT ratio, i.e. 1 Amp or 5 Amp current transformer secondary.
CT Primary Current Ratio menu 125

Sets the ratio of the current transformers.
The set value is the ratio (Primary : Secondary), and is illustrated by the following examples:
for 1000 to 5 CTs the ratio being 200
The display also shows the calculated CT “label ratio” eg. 1000 : 5, 2400 : 5, 1500 : 1 etc.
Module Setup – Sub Menu
Module Number menu 131

This is the module number for the Si-TEC LAN communications. All modules controlling generators
on a single system must have a unique number, typically from 1 to 22.
Pin Number for User Access Code menu 133

This allows the user to set a personalised identification to enable the modification of set point
values. The factory setting is shipped at “3”. Should the PIN number be forgotten, a numeric value
of “7654321” should be entered to revert to the factory set PIN of “3”. This provides for access even
with a misplaced PIN number, and also provides notification to the supervisor that the number has
been configured to the factory setting. For security, the “Access” PIN is not displayed when viewing
this menu item.
16
Set Master Priority 0 for unit#0, 1=#23 menu 134
Provides for two Si-TEC Xtend GSM master modules in a single system. Should both GSM master
modules be “enabled” to control at the same time, the generator will accept command from the
Priority Master only. This means that each Si-TEC Xtend module will look at the Priority Master
module to verify that master is in control. If there is a communication timeout or a
hardware/software failure in the Priority master module, the modules will then turn to the other
master module.
RS232 baud rate 2400 to 38400 baud menu 135

Sets the baud rate of the Si-TEC RS232 port. Nominally set at 9600.
RS232 Word Endian 0=big 1=little menu 136

For 32 bit data transfer sets the first 16 bits as the HIGH 16 bits or the LOW 16 bits.
0 = HIGH 16 bits transmitted first followed by the LOW 16 bits.
1 = LOW 16 bits transmitted first followed by the HIGH 16 bits.
User RS485 Address menu 137

Sets the “Node” number for the user RS485. This may be set from 1 to 255.
For most instances is this would be set the same as the module number as in menu item 131
above.
User RS485 Mode 0 = ASCII 1 = RTU menu 138

Sets the “Modbus” protocol for the User RS485 communications.
User RS485 Response delay menu 139

Sets the delay time between request from the communications master to the Si-TEC Xtend module
response. Usually set at 3mSec, with a range of 2 to 100mSec.
User RS485 W.Endian 0=big 1=little menu 140

For 32 bit data transfer sets the first 16 bits as the HIGH 16 bits or the LOW 16 bits.
0 = HIGH 16 bits transmitted first followed by the LOW 16 bits.
1 = LOW 16 bits transmitted first followed by the HIGH 16 bits.
Alarm On Stretch Time for Si-TEC LAN menu 141

Allows the alarm issued via the Si-TEC LAN to be logged or “stretched” for a specified time. Usually
set at 10 seconds, with a range of 1 to 600 seconds.
17
3.5 SPEED GOVERNOR – Control Function – Main Menu
Speed Control – Set Point Parameters – Sub Menu
Backup MPU Connected to MPU Input No 2 menu 177

Set this to “Yes” if a secondary MPU is being utilised, else set to “No”. When set to “No” the
secondary MPU fail alarm is disabled. However, the second MPU will still function and provide
redundancy operation if connected.
Teeth per Turn on MPU Gear menu 178

Is the number of teeth on the gear sensed by the MPU .
Gear Reduction Ratio menu 179

Is the gear ratio between the prime mover main shaft and the MPU sensed shaft.
For sensing of the flywheel teeth this ratio is 1.0000.
Where the sensed gear runs slower than the main shaft a typical ratio could be 2.4573.
Where the sensed gear runs faster than the main shaft a typical ratio could be 0.7500.
(adjustable from 0.1000 to 20.0000)
MPU Failure Shutdown - Bypass on Start up menu 180

When set to "NO", the MPU pulses must be received before the actuator moves from the zero fuel
position. If set to "YES" the actuator will move from zero to the Start Limit position without the
sensing of MPU pulses. Should the MPU frequency on cranking be under approx 200 Hz, it may be
necessary to set the ‘By Pass Fail Safe’ function to "YES" ‘.
Idle Speed RPM / Idle Hold Time / Rated Speed Logic Input
Menu items: Idle Speed RPM menu 181
Idle Hold Time (seconds) menu 182
The generator will ramp to the idle speed and operate at the idle speed for a preset idle delay time,
the set will then ramp to the rated speed. Should "Rated Speed" be assigned as a logic input the
generator will continue to run at the idle speed until the rated speed logic input is switched “High” .
The rated speed input may be permanently assigned as “always ON” (1) in the configuration menu.
This would always ramp the set to running speed (after the idle delay) without energising an
assigned input.
Refer to the menu ‘Configuration of Logic Inputs’.
Ramp to Rated Speed / Fast Ramp to Rated Speed - in % per second of Rated Speed
Menu items: Ramp to Rated Speed menu 183
Fast Ramp to Rated Speed menu 184
The generator speed will increase and decrease in speed at the selected ramp rate. This applies to
the no load operation of the generator.
The Fast Ramp is operative if the "Fast Rate" logic input is assigned as a logic input and the input
made High. The intent of using fast rate is to have steady ramp rates for normal operation and
introduce a faster ramping facility for emergency start up.
(eg. stand-by power systems or power station generator failure)
Rated Speed RPM (operating speed) menu 185

This is the operating speed of the prime mover and must be set to match the operating frequency of
the generator. ie. with a 4 pole alternator and a frequency of 50 Hz the speed should be set for
1500 RPM. If a geared reduction is used in driving the alternator the precise engine speed for the
correct frequency must be set.
18
Warm-Up Time at Rated RPM (in minutes 0.0) menu 186
The warm-up time is the time the generator operates at the rated speed for warm-up prior to
synchronising and paralleling. The warm-up time is bypassed should the "Fast Rate" logic input be
assigned and switched to “High”.
Engine Cool Down Speed RPM menu 187

This sets the speed for the engine cool down period. Normally, this is set at the rated speed.
Engine Cool Down Time (in minutes 0.0) menu 188

Following the ramping down of the load and opening of the Circuit Breaker, the generator will run at
the rated speed for a preset “Engine Cool Down” time before shutting down.
Should logic input 1 "Engine Run" be de-energised the Si-TEC Xtend module will provide an
immediate CB Trip Signal, de-energise the fuel solenoid and drive the actuator to zero fuel.
Over Speed Test Maximum RPM menu 189

When conducting the Si-TEC Xtend over speed trip test, this function sets the maximum speed that
the engine will ramp to for the test. It is intended that this speed setting be slightly higher than the
Over Speed Trip setting of the independent external protection system.
Start Sequence – Actuator – Sub Menu
Start Fuel Limiting Actuator Position % / Increase Actuator Limit Position % per Sec
Menu items: Start Fuel Limit Actuator Position menu 198
Increase Actuator Limit Position % per sec menu 199
Upon initial starting/cranking of the set the actuator will move to the “Start Fuel Limit” position and
then increases at the preset rate until the engine starts. This facility prevents over fuelling when
starting, but guarantees the engine start with the governor actuator moving to full fuel if required.
Max Actuator Position when Starting in% menu 200

During the start sequence the actuator position will not exceed this setting. This maximum limit is
released when the engine achieves running speed.
Max Actuator Position when On-Line in% menu 201

With the generator paralleled and loaded, the actuator will not exceed this setting.
Use “Start Limit” on all “Crank Attempts” menu 202

When set to “Yes” the actuator will revert to the “Start Limit” position for each subsequent start
attempt. When set to “No” the actuator will revert to the position when the previous cranking attempt
was terminated.
Gas Purging Crank Time “First Crank” / No of Purge Cranks / Actuator Position During
Purge
Menu Items: Gas Purging Crank Time “First Crank” menu 203
No of Purge Cranks menu 204
Actuator Position During Purge menu 205
For gas fuelled engines a purge cycle is available. The “Gas Purging Crank Time” first crank
determines this purge time. The “Actuator Position During Purge” sets the required throttle position
for the purge cycle. On completion of the purge cycle, the normal crank cycle commences without a
“Wait Time”. The actuator is positioned as set in Menu 198 (“Start Fuel Limit”), with the Fuel
Solenoid being energised.
Crank Cut-out RPM / Crank On Time / Cranking Off Time / Number of Crank Attempts
Menu Items: Crank Cut-out RPM menu 206
Crank On Time menu 207
Crank Off Time menu 208
Number of Crank Attempts menu 209
19
If a relay output has been assigned for the cranking facility (refer to the configuration menu) this
function will provide a number of cranking attempts (with preset “On” and “Off” times) until the
“Crank Cut-out RPM” is achieved or if the “Number of Crank Attempts” is completed.
A “Start Failure” relay output alarm may also be assigned from the ‘Relay Output Configuration’
menu if required.
“Crank On Time” (in seconds) is the cranking time period, while “Crank Off Time” (in seconds) is the
pause time between “Crank On Time” periods.
Note: If the “Fuel Solenoid” relay output is being used to initiate a start via an engine control
including crank cycle, the number of crank attempts should be set to “0”.
Max “Pre-Heat Time” Pre Crank / Pre-Heat between Crank Attempts

Menu Items: Max “Pre-Heat Time” Pre Crank menu 210
Pre-Heat between Crank Attempts menu 211
The pre-heat facility is available using a logic input function. The “Pre Heat Complete” function may
be allocated to a logic input terminal, or set to always OFF or always ON. When this logic input is
switched to “High” the pre-heat terminates. Accordingly, if this function is never required the “Pre
Heat Complete” may be configured to “always ON’. If configured to “always OFF”, the pre-heat
function operates during each starting cycle of the engine.
Manual Start Time out in Seconds menu 212

This time provides for “Start Fail Alarm” where the Si-TEC Xtend cranking cycle in not utilised.
PID Adjustments – Speed Loop Response – Sub Menu
P.I.D. DEFINITIONS
PROPORTIONAL
Proportional is the amount of correction (gain) factor required for a given speed/load error.
Proportional settings “P” range from 1 to 99
Increasing the value will increase the gain.
INTEGRAL
Integral is the time constant (stability) for the proportional correction.
Integral settings “I” ranges from 1 to 99
Increasing the value will decrease the time constant
DERIVATIVE
Derivative is the amount of correction in relation to the RATE OF CHANGE of the speed/load error.
(it is NOT the amount of error)
Derivative settings “D” ranges from 0 to 99
Increasing the value will increase the derivative.
Note: Incorrect derivative values may result in jiggling of the actuator.
The constants used for adjusting the PIDs provide for similar response change across the major
span of adjustments ie. from 20 to 80. Beyond these values the response change to the PID
constants would require more coarse adjustments. Typically a small change in value of the PID
constants would result in a significant dynamic response change of the governing control. Also refer
to additional Speed PID section in this manual.
Idle Proportional / Idle Integral / Idle Derivative

Menu items: Proportional at Idle RPM menu 232
Integral at Idle RPM menu 233
Derivative at Idle RPM menu 234
These are the P.I.D. settings controlling at IDLE SPEED.
20
The Idle Proportional is the gain characteristic. Decreasing the Idle Proportional setting will lower
the sensitivity response to speed change. If the Idle Proportional is set too high a fast oscillation of
speed would result.
The Idle Integral is the stability factor of the PID and is tuned relative to the Idle Proportional (gain).
A high setting of the Idle Integral would result in a slow oscillation of the engine at idle speed. The
Idle Integral is tuned in conjunction with the Idle Proportional constant to obtain the optimum
steady-state speed response. The Idle Derivative value should be set low for responsive engines
and actuators (eg. 0 to 30).
Rated Proportional / Rated Integral / Rated Derivative

Menu items: Proportional at Rated RPM menu 235
Integral at Rated RPM menu 236
Derivative at Rated RPM menu 237
These are the P.I.D. settings controlling at the RATED SPEED.
The Rated Proportional is the gain characteristic. Decreasing the Rated Proportional setting will
lower the sensitivity response to speed change. If the Rated Proportional is set too high a fast
oscillation of speed would result.
The Rated Integral is the stability factor of the PID and is tuned relative to the Rated Proportional
(gain). A high setting of the Rated Integral would result in a slow oscillation of the engine at rated
speed. The Rated Integral is tuned in conjunction with the Rated Proportional constant to obtain the
optimum steady-state speed response. The Rated Derivative value should be set low for
responsive engines and actuators (eg. 0 to 30).
Paralleled Proportional / Paralleled Integral / Paralleled Derivative (CGC modules only)

Menu items: Proportional Paralleled to Grid menu 238
Integral Paralleled to Grid menu 239
Derivative Paralleled to Grid menu 240
These are the P.I.D. settings controlling when Paralleled to the GRID.
The Paralleled Proportional is the gain characteristic. Decreasing the Paralleled Proportional
setting will lower the sensitivity response to load change . If the Paralleled Proportional is set too
high a fast oscillation of load would result.
The Paralleled Integral is the stability factor of the PID and relative to the Paralleled Proportional
(gain). A high setting of the Paralleled Integral would create a slow oscillation of the generator load.
The Paralleled Integral is tuned in conjunction with the Paralleled Proportional constant to obtain
the optimum steady-state load response. The Paralleled Derivative value should be set low for
responsive engines and actuator (eg. 0 to 30).
Typically the Paralleled P.I.D. settings are required to be set lower than the rated PIDs.
Comparative "Rated P.I.D." and "Paralleled P.I.D." settings for a gas engine could be:
Proportional Integral Derivative
Idle 20 40 10
Rated 55 60 25
Paralleled 25 40 10
Also refer to the "Performance Enhanced " and "Multi Point On-Load PID" menus below.
Actuator Disturbance (Bump Magnitude) / Actuator Disturbance (Bump Duration)

Menu items: Actuator Disturbance (Bump Magnitude) menu 242
Actuator Disturbance (Bump Duration) menu 243
To enhance dynamics tuning the actuator may be "Bumped" using the Si-TEC Xtend module. The
“Bump Magnitude” (%) is set to decrease the actuator position. The “Bump Duration” (seconds) is
the time duration required for the "Bump". Push the “BUMP” button on the key pad to operate the
21
disturbance. While this function may be used when the generator is unloaded or loaded, care must
be taken when setting the value of the magnitude and duration before the “bump” test is performed.
Disturbance DELAY after ‘Pressing Bump’ menu 244

A menu item “Disturbance Delay after pressing Bump” will delay the operation of the actuator
BUMP for that set period.
Performance Enhanced – PID Adjustments – Sub Menu
Fast Response Per Cent / Fast Response Proportional / Fast Response Integral
Menu items: Do Fast Response when out of % Band menu 251
Fast Response Proportional Gain Multiplier menu 252
Fast Response Integral Multiplier menu 253
Fast Response Per Cent (%) is the percentage of speed error where the fast response multipliers
become active. Nominally set to 1.5%.
Fast Response Proportional is the multiplying factor to the Rated Proportional Setting and
operates when the speed error is beyond the setting of the Fast Response per cent. This is
nominally set to 1.5. Increasing the preset value will increase the actuator gain. Reduce the Fast
Response Proportional value should excessive actuator overshoot be apparent and if the Rated
Proportional is optimally set. The Fast Response Proportional may also be utilised during the
synchronising and load control modes.
Fast Response Integral is the multiplying factor to the Rated Integral Setting and operates when
the speed error is beyond the setting of the Fast Response per cent. This is nominally set to 2.0.
Increasing the preset value will increase the actuator integral response. Reduce the Fast Response
Integral value should the actuator show instability and if the Rated Integral is optimally set. The Fast
Response Integral may also be utilised during the synchronising and load control modes.
Speed PI Multiplier Hold Off time menu 265

This inhibits the enabling or action of the PI Multiplier response, until after the specified hold off
time. Nominally set to 3.0 seconds, with a range of 0 to 60 seconds.
Do Rapid Response on Gen Breaker Trip menu 254

When set to “YES” this provides a more responsive correction of the rated speed, minimising speed
overshoot when the generator breaker is tripped.
Do Rapid Response on Mains CB Trip menu 255

When set to “YES” this provides a more responsive correction of the rated speed, minimising speed
overshoot when the mains CB trips. This function is used when the operation is to export power.
Use Torsional Filter (Y, N) for Control menu 258

When enabled (set to “Y”), this function will provide the filtering of engine torsionals, to minimise
actuator “jitter” or “jiggling”. This function is nominally set to “Y” (i.e. torsional filter enabled).
Multi Point On-Load PID – Island Mode – Sub Menu
These PID settings only function in “islanded mode” operation if menu item 271 is set to ‘yes’ and
they do NOT operate when the generator is paralleled to the mains supply (grid).
Also refer to the “Speed PID” section of this manual.
Enable Multi point On-Load speed PIDs menu 271

This function is used when the dynamic response of the engine-generator varies from no load to full
load. When set to "YES" the On-Load PIDs are operative. The PID settings integrate from the
Rated PIDs to the Mid Point (adjustable from 0% to 99% load) to the 100% Load PIDs.
For most applications this function is set to "NO".
22
100% Proportional / 100% Integral / 100% Derivative
Menu items: Proportional Gain at 100% kWatt Load menu 272
Integral at 100% Load menu 273
Derivative at 100% Load menu 274
These are the P.I.D. settings controlling at 100% load. The PIDs integrate from the Mid Point
settings to the 100% Load settings.
% Load of Rated kWatt for Mid Point PID

Menu item: Proportional Gain Mid Point kWatt Load menu 275
This is the percentage of the engine-generator rated kWatt load when the Mid Point PID settings
become operative.
Mid Point Proportional / Mid Point Integral / Mid Point Derivative

Menu items: Proportional Gain Mid Point kWatt Load menu 276
Integral at Mid Point kWatt Load menu 277
Derivative Mid Point kWatt Load menu 278
These are the PID settings controlling at the selected mid point. The PIDs integrate between the
Rated Speed PID settings, the Mid Point PID settings, and the 100% Load PID settings.
23
3.6 GENERATOR / ALTERNATOR – Control Function – Main Menu
FREQUENCY Set Point Parameters – Sub Menu
Rated Frequency / Follow Bus to Min Hz Limit / Follow Bus to Max Hz Limit
Menu items: Rated Frequency (Hz) menu 287
Follow Bus Freq to Min Limit (in % of rated) menu 288
Follow Bus Freq to Max Limit (in % of rated) menu 289
The Rated Frequency is the generator operating frequency set to match the desired system
frequency (eg. 50Hz). The Minimum Limit is set to a level below the operating frequency (eg. 96%).
The Maximum Limit is set to a level above the operating frequency (eg. 104%). Hence, there will be
a corresponding increase (when Bus frequency decreases) and a decrease (when Bus frequency
increases) of the generator kWatt output.
When paralleled to the supply grid the Si-TEC Xtend control will not correct beyond the minimum or
maximum limit frequency settings. This protects the system should there be any incorrect
information (eg. Gen CB relay is faulty, mains C.B auxiliary input is faulty etc).
NOTE: The Rated Frequency setting must correspond to the engine rated speed setting.
SYNCHRONISING Set Point Parameters – Sub Menu
Proportional (Gain) Synchroniser Control menu 301

Synchronising Proportional is the value of speed gain while the generator is synchronising. This
value provides a bias to the preset Rated Proportional (gain).
Integral Synchroniser Control menu 302

This represents the time constant (stability) for the Synchonising Proportional correction.
Max Hz Bias to Correct Phase Error menu 303

Maximum Hz Bias is the range above or below the synchronising frequency, that will "bias" the
incoming generator to correct any frequency error between generator and bus. For diesel engines
this is typically set at 2.0 and for gas engines typically set at 0.5.
Hz Higher Sync Only menu 304

If “Hz High Sync Only” is selected as "YES", synchronising will only occur if the generator is at a
marginally higher frequency. This ensures that the initial power flow is from the incoming generator.
Maximum Slip Frequency menu 305

This is maximum variance of speed for synchronising. This is nominally set at 0.10 Hz and may be
adjusted in steps of 0.01 Hz. The recommended maximum setting is 0.18 Hz.
Phase Angle Window menu 306

The synchronising phase angle of the incoming generator set must be within the set window angle.
This is nominally set at 6 deg, with a suggested maximum phase angle of 12 deg.
Phase Matching Offset Compensation menu 307

The offset compensates for any phase shift between the voltage sensing inputs, and is expressed
in degrees + / -. This may be used to compensate for shifts in phase voltage sensing. This is
normally set to 0.
No Sync. if Bus Hz Below % of Rated menu 308

Should the bus frequency be below this setting the generator will maintain the operating frequency
and will not attempt to synchronise. The nominal setting is 96%.
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No Sync. if Bus Hz Above % of Rated menu 309
Should the bus frequency be above this setting the generator will maintain the operating frequency
Sync Exit Time menu 310

Upon synchronising and closure of the Generator CB (via Gen CB aux contact) the generator will
remain in the synchronising mode during this period of time. This will provide a minimum delay
before the ramping of generator kWatt and kVAr load. Should there be a delay between closing of
the auxiliary contact and the circuit breaker main contacts, the synchronising mode is maintained
for a preset time. The time range is from 0.0 to 1.0 sec and is typically set at 0.1 seconds.
Voltage Match Window menu 312

The Voltage Match Window is the desired range of generator voltage that permits closure of the CB
when synchronising with the bus. This requirement is in addition to the matching of the frequencies
and phase angle. The Voltage Match Window should be set greater than the Voltage Dead Band. If
no voltage trimming is used this value may be set to 10% to 15% of the generator rated (ph/n)
voltage.
Voltage Match Offset Compensation menu 313

This offset compensates for differences between the voltage sensing inputs. It also ensures the
positive flow of kVArs from the generator upon synchronising and CB closure by allowing the
incoming generator to be 0.5 to 1.0 % higher than the bus voltage. This value is expressed in Ph/N
Volts. This is normally set to 0%.
No Sync. if Bus Volt Below % of Rated menu 314

Should the bus frequency be below this setting the generator will maintain the operating frequency
No Sync. if Bus Volt Above % of Rated menu 315

Should the bus frequency be above this setting the generator will maintain the operating frequency
VOLTAGE / AVR Control – Sub Menu
Voltage Proportional / Integral

Menu items: Proportional (Gain) Voltage Control menu 326
Integral Voltage Control menu 327
These are the P.I. settings for controlling the AVR Bias Output. The proportional is the gain
characteristic. Decreasing the proportional will lower the sensitivity response. If the proportional is
set too high, over correction of voltage would result. The Integral is the stability factor of the P.I. A
high setting of the Integral would create a slow oscillation of the AVR voltage control. The Integral is
tuned to obtain optimum response of the voltage stability. The response of the voltage Si-TEC
Xtend voltage P.I. should be tuned to lag the response of the AVR stability control.
AVR Control Method menu 328

Select “0” for relay output for Voltage trim Raise / Lower. Select “1” for analog AVR bias control.
Gen Rated Voltage ph/ph - ph/n menu 329

Set the “Gen Rated Voltage” to the desired system voltage. The preset value is adjusted to set the
Phase to Neutral (star point) voltage. The Phase to Phase voltage may also be calculated and
displayed.
Voltage Dead Band % of Rated Voltage menu 330

This is the span or Dead Band relative to the Rated or System Voltage at which no correction
adjustment is made. If the Dead Band is set very tight (low value) it may cause a continuous
correction adjustment for very small changes. Suggested Dead Band settings would be 1% to 1.5%
of the Rated Voltage for MOP (raise/lower) trimming and 0.0 to 0.5% if the analog AVR Bias Output
is utilised.
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NOTE: The voltage dead band should always be set less than the ‘synchronising voltage matching
window’ to ensure adequate voltage trim control during synchronising.
Voltage Control Delay Before Active menu 331

This is the delay on start up. After the generator is above the “No Sync if Bus Hz Below (% of
rated)” [menu 308], and above the “No Sync if Bus Volts Below (% of Rated)” [menu 314], this
represents the delay time before the voltage trimming control commences. Typically set at 0.5 secs.
Follow Bus Volts to Min Limit % / Follow Bus Volts Max Limit %
Menu items: Follow Bus Volts to Min Limit (in % or rated) menu 332
Follow Bus Volts to Max Limit (in % or rated) menu 333
Set Minimum Volts to a level below the operating frequency, say 90%.
Set Maximum Volts to a level above the operating frequency, say 110%.
When paralleled to the supply grid the Si-TEC Xtend control will not correct beyond the minimum or
maximum voltage settings. Should the bus voltage rise above the maximum voltage limit setting,
the generator would not continue to follow that voltage. Subsequently in trying to maintain the
voltage there will be a corresponding decrease in kVAr load from the generator, possibly resulting
in leading kVArs. This may result in Reverse kVArs (Under Excitation) alarm.
Similarly, if the bus voltage is beyond the minimum voltage limit setting, this will result in an
increase in kVAr load from the generator.
This operation is required to protect the system against incorrect information (eg. Mains C.B closed
input is faulty)
Min. AVR Bias Voltage from Si-TEC Xtend module / Max. AVR Bias Voltage from Si-TEC
Xtend module
Menu Items: Min AVR Bias Voltage from Si-TEC Xtend module menu 334
Max AVR Bias Voltage from Si-TEC Xtend module menu 335
This is the minimum and maximum voltage bias output levels that the Si-TEC Xtend module will
bias the AVR. This should be set to provide the generator with the required voltage adjustment
span to provide adequate compensation for the generator voltage droop, AVR drift, and utility
voltage swings.
All generators should have similar span adjustment range settings, ensuring similar minimum and
maximum generated voltage output levels (ph/ph). The bias preset values are also set in
conjunction with the AVR unit’s minimum and maximum voltage bias range. The “Null” bias point is
the midpoint between the minimum and maximum settings. The “Null” bias level is used on initial
generator start up / excitation.
Note: Refer to appendix for detail of settings to suit of various AVR makes and models.
AVR Bias Disturbance Bump Magnitude (test) / AVR Bias Disturbance Bump Duration (test)
Menu items: AVR Bias Disturbance - Bump Magnitude menu 336
AVR Bias Disturbance - Bump Duration menu 337
To facilitate optimum tuning the AVR, the bias signal to the AVR may be "Bumped" via the Si-TEC
Xtend module. The Disturbance Magnitude is set to provide a step decrease in the AVR Bias
Output. The Disturbance Duration is the time required for the "Bump". To operate the disturbance
the “BUMP” button on the keypad should be pushed. This function enhances the tuning of the
Voltage and kVAr dynamics (PI).
AVR Bump Delay Time after “Pressing Bump” menu 338

A menu item “AVR Bump Delay Time after pressing Bump” will delay the operation of the AVR
biasing BUMP for that preset period.
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kWatt Control – Set Point Parameters – Sub Menu
Proportional (Gain) kWatt Control menu 346

The kWatt Proportional is the gain characteristic of the P.I. settings for kWatt load sharing and
kWatt control. Decreasing the proportional setting will lower the load sharing or kWatt control
sensitivity response. If the proportional is set too high, a fast oscillation of the kWatt load results.
Integral kWatt Control – (CGC operation only) menu 347

This operative only when the generator is paralleled to the supply grid. The Integral is the stability
factor of the P.I. and is relative to the kWatt proportional. A high setting of the Integral would create
a slow oscillation of the kWatt load. The Integral is tuned to obtain optimum kWatt control stability.
kWatt Dead Band % of Rated kWatt – (CGC operation only) menu 348
The kWatt dead band in only operative when running paralleled to the supply grid. The kWatt Dead
Band is set for approx 0.5% of the generator rated kWatts.
Rated kWatt of Generator menu 349

This is the kWatt Rating of the generator that is used to ensure proportional load sharing of the unit
with other generators.
Re-Rated Generator kWatt menu 350

This is the revised rating of the generator kWatt load and is activated by the logic input "kWatt De-
Rate". This input may be disabled by setting the input value to “always OFF”. Refer to the
Configuration Menu.
If this function is not used, it is recommended that the value be set the same as the rated kWatts
and the "kWatt De-Rate" logic input function be set to "always OFF".
Grid Paralleled kWatt Set Point – (CGC operation only) menu 351
This set point value is used under the following conditions:
a) CGC only - When paralleled to supply grid with no GSM master reference or when a 4-20mA
input for external kWatt reference is not used.
b) CGC only- When under the control of a GSM master and if the “Enable Load Share” function is
de-energised (switched “Low” or set to “always OFF”), and if no 4-20mA reference is installed.
Jump to Min. kWatt when Closing CB menu 352

The generator will “jump” to this kWatt level immediately after the closure of the circuit breaker
(CB). Normally the “Jump to Minimum kWatt” is set to 0 kWatt.
Warm Up Load Level kWatt Set Point / Warm Up on Duration at kWatt Set Point
(CGC operation only)
Menu Items: Warm Up Load Level kWatt Set Point menu 353
Warm Up on Duration at kWatt Set Point menu 354
This provides warming up of a generator at a preset kWatt load and for a preset time duration.
Coming OFF LINE Open Gen CB at % of Rated / Coming OFF LINE Open Gen CB Time-out
Menu Items: Coming OFF LINE Open Gen CB at % of Rated menu 355
Coming OFF LINE Open Gen CB Time-out menu 356
This provides a kWatt level for opening of the generator CB when ramping down the kWatt load to
come “Off Line”. This provides for switching at low current and kWatt levels.
Should this kWatt level not be achieved (eg. last generator on), the open CB signal will be activated
after the preset time-out. This time commences from de-energising the logic input terminal 2 (Start
Seq.) of the Si-TEC Xtend module.
Base Load Mode (1) kWatt Set Point / Base Load Mode (2) kWatt Set Point
Menu Items: Base Load Mode (1) kWatt Set Point menu 357
Base Load Mode (2) kWatt Set Point menu 358
These are the kWatt set point values that operate when the “Base Load” logic input functions are
activated. Should an external 4-20mA input be used as the “Base Load” reference, these values will
assume the “Base Load” set point should the 4-20mA input signal reference fail.
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Load (ON) Ramp Rate at % /sec of Rated kW / Load (OFF) Ramp Rate at % /sec of Rated kW
Menu Items: Load (ON) Ramp Rate at % /sec of Rated kW menu 359
Load (OFF) Ramp Rate at % /sec of Rated kW menu 360
These are the kWatt (in % of Rated kW) Ramp Rates for loading and unloading of the generator.
The Load Rates do not affect sudden load changes on "Islanded" operating power stations, and
relate to the on-line and off-line ramping of the generator. This provides "Soft" (bumpless) loading
and unloading of the generator.
Fast Load (ON) Ramp % /sec of Rated kW / Fast Load (OFF) Ramp % /sec of Rated kW
Menu Items: Fast Load (ON) Ramp % /sec of Rated kW menu 361
Fast Load (OFF) Ramp % /sec of Rated kW menu 362
These are the kWatt (in % of Rated kW) Ramp Rates for loading and unloading of the generator
when the “Fast Rate” logic input is “High”. The Load Rates do not affect sudden load changes on
"Islanded" operating power stations, and relate to the on-line and off-line ramping of the generator.
This provides faster but controlled loading and unloading of the generator.
Enter Approx Actuator Position at “No Load” menu 363

The No Load actuator position is set to the position of the actuator when the set is running at
operating (rated) speed under no load conditions. The actuator position is displayed on the LCD
screen and the no load actuator position should be set to match the actual value. This setting does
not need to be precise, but the recommended setting should be within 3% of displayed value.
Enter Approx Actuator Position at “Max Load” menu 364

The Maximum Load actuator position is set to the position of the actuator when the generator is
running at operating (rated) speed at full load. The actuator position is displayed on the LCD and
the full load actuator position should be set to match the actual value. This setting does not need to
be precise, but the recommended setting should be within 3% of displayed value. Should full load
not be available, the recommended setting is around 90% (used for actuator position droop).
Minimum Import kWatt when Closed to Grid (CGC operation only) menu 365
This is used on a single or dual generator application where a GSM module it not utilised. A kWatt
bi-directional transducer provides a 4-20mA input representing import/export kWatt to the Si-TEC
Xtend module. The “Minimum Import kWatt can be set as a positive value for import or a negative
value if the limit is at export. The “Minimum Import” function is operated as a limit, limiting the
generated kWatts.
(Refer to Logic Input Functions to enable this feature)
Import kWatt (1) when Closed to Grid (CGC operation only) menu 366
This is used on a single or dual generator application where a GSM master it not utilised. A kWatt
bi-directional transducer (user supplied) provides the 4-20mA input representing import/export
kWatt to the Si-TEC Xtend module. This “Import kWatt” acts as the reference kWatt for the
generator. The “Import kWatt can be set as a positive value for import or a negative value should
the kWatt load be used for export. Failure of the 4-20mA input will result in the generator operating
under the “Import kWatt (1) when CLOSED to GRID” (menu 366) reference.
(Refer to the “Sum Import Sensors Select” logic input function to enable this feature)
Import kWatt (2) when Closed to Grid (CGC operation only) menu 367
This operates as menu item 366 above and provides a secondary preset “Import kWatt” reference
value. Changing between the two “Import kWatt” references can be conducted by using logic input
functions.
(Refer to the “Sum Import Sensors Select” logic input function to enable this feature)
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kVAr / Power Factor Control – Sub Menu
Proportional (Gain) kVAr / PF Control menu 381

The kVAr proportional is the gain characteristic of the P.I. settings for kVAr/PF sharing and kVAr/PF
control. Decreasing the proportional setting will lower the load sharing or kVAr/PF control sensitivity
response. If the proportional is set too high, a fast oscillation of kVAr load would result.
Integral kVAr / PF Control menu 382

The Integral is the stability factor of the P.I. and relative to the kVAr/PF proportional. A high setting
of the Integral would create a slow oscillation of kVAr load. The Integral is tuned to obtain optimum
kVAr control stability.
kVAr Dead Band % of Rated kVAr – (CGC operation only) menu 383
The kVAr dead band in only operative when running paralleled to the supply grid. The kVar Dead
Band is set at approximately 0.5% of the generator rated kVArs.
Rated Power Factor of Generator menu 384

The “Rated Power Factor” is set based on the power factor rating of the generator, or nominal set at
0.80 P.F. This setting also operates as a lagging kVAr limit (positive generator kVArs) for the kVAr
control when paralleled to the supply grid.
Paralleled to Grid PF Set Point – (CGC operation only) menu 385

input external PF reference is not used.
b) CGC only- When under the control by a GSM master and if the “Enable Load Share” function is
de-energised (switched “Low” or set to “always OFF”) and if no 4-20mA PF reference is used.
(also see Paralleled to Grid kVAr set point – and menu Item 393 kVAr or PF [grid] control)
Paralleled to Grid kVAr Set Point – (CGC operation only) menu 386
input external kVAr reference is not used.
b) CGC only- When under the control by a GSM master and if the “Enable Load Share” function is
de-energised (switched “Low” or set to “always OFF”) and if no 4-20mA kVAr reference is used.
(also see Paralleled to Grid PF set point – and menu Item 393 kVAr or PF [grid] control)
Leading kVAr Rating menu 387

This value corresponds to the leading kVAr alarm setting. The alarm is expressed as a percentage
of rated leading kVAr.
For CGC modules: This value should correspond to the maximum value (control limit of negative
kVArs) for leading kVArs (or leading power factor) when the generator is paralleled to the supply
grid.
Base Load Mode (1) PF Set Point / Base Load Mode (2) PF Set Point
Menu Items: Base Load Mode (1) PF Set Point menu 388
Base Load Mode (2) PF Set Point menu 389
These are the Power Factor set point values that operate when the base load function is activated.
Maximum On-Time for AVR / MOP Driver Relays menu 390

This provides for reducing/increasing the “on-time” of the raise/lower relay output signals driving a
motor operated potentiometer or a AVR requiring logic raise/lower signals.
The on-time is a facility in addition to the Volts and kVAr Proportional and Integral (P.I.) adjustments
kVAr Delay Band in % of Rated / kVAr Delay Band Correction Delay

Menu Items: kVAr Delay Band in % of Rated menu 391
kVAr Delay Band Correction Delay menu 392
The function is typically not required when utilising the analog AVR biasing facility.
For analog AVR biasing typically set both these to “0”
29
Where the connected load has a constant swing in the reactive load, a delay in the correction to the
kVAr can minimise unnecessary operation of the trimming motor operated potentiometers. The
kVAr error is required to be (1) beyond the “Dead Band” (menu 383), (2) within the “Delay Band %”
and (3) after completion of the “Correction Delay” time period, for kVAr error correction to
commence. The error is then corrected to within the kVAr dead band value (menu 383). Should the
kVAr error be beyond that of the “kVAr Delay Band %” the correction of the kVAr will commence
immediately. This facility provides a slow band of operation for kVAr control.
kVAr or PF (Grid) Control menu 393

This sets the method of referencing for system kVAr or PF control when running the generator(s)
paralleled to the utility grid (if a GSM master is not used or is disabled). Refer to menu items 385
and 386 above. A setting of ‘0’ is kVAr control, a setting of ‘1’ being power factor control. This is
nominally set to ‘1’.
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3.7 MANUAL MODE – Set Point Parameters – Main Menu
Manual Mode Speed DROOP (see next Menu) menu 401

Sets the Droop % based on generator kWatt output or actuator position. Droop only functions when
the Si-TEC Xtend module is in “Manual” mode. In the “Auto” mode the governor controller operates
in an isochronous operation. The actuator position droop is the droop across the speed span set in
menu items 403 and 404 below. Refer to menu 402 for details on droop control.
Select droop mode 0=kW or 1=actuator menu 402

For generator application kWatt droop (0) is recommended. This provides a linear droop across the
full kWatt operation (no load to full load) of the generator.
The following description is based on the generator being paralleled to a load bus or the supply
grid:
The setting of “1” (actuator droop) may be utilised during commissioning when confirming the
correct current transformer (CT) polarity. With ”actuator droop” the generator will continue to take
kWatt load even if the polarity of the CTs is reversed.
a) Set the droop mode to “1”.
b) Set the droop % to about 5%.
c) Immediately after the generator has synchronised switch the Si-TEC Xtend to “manual” mode
(“Auto” input switched to “Low”). This will hold the kWatt load steady even if the CTs are reversed.
d) Check the kWatt displayed for each phase in the generator information display.
e) In the “manual mode" operate the “Increase Speed” input. This will increase the speed
reference, resulting in an increase of the kWatt load of the generator.
f) Verify the kWatt display for an increase in positive kWatt. Positive kWatts should be
displayed for all three phases. Should any phase show a negative value, shut down the generator
and reverse the C.T. connections of the phases displaying negative kWatt.
g) Perform steps (e) and (f) again until correct CT polarity is confirmed.
h) Set the Droop Mode back to “0”
In Manual Mode what is the Desired Min RPM menu 403

This sets a minimum limit that the decrease speed will control under the Si-TEC Xtend manual
operation
In Manual Mode what is the Desired Max RPM menu 404

This sets a maximum limit that the increase speed will control under the Si-TEC Xtend manual
operation
Manual Adjust Rate RPM per Second menu 405

This sets the rate of change in RPM per second when operating the Si-TEC Xtend in manual mode.
The speed adjustment is performed when operating the Manual Speed Raise/Lower logic inputs.
AVR Bias Voltage starting in manual menu 406

When starting the generator in manual mode the AVR bias is set to this voltage level.
AVR Bias Voltage ramp rate Vdc/sec menu 407

This sets the dc voltage level to ramp the voltage bias signal to the AVR. Typically start with a low
value (say 0.5 Vdc) and increase to suit the generator voltage output ramp rate requirement.
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3.8 LOGIC and ANALOG I/O – Configure – Set Parameters – Main Menu
Logic Inputs – Allocate a Task to an INPUT – Sub Menu
The following logic input functions can be set to:

always OFF : always ON : or allocated to a switched logic input terminal.
Some items cannot be set to “0” always off.
Terminal allocation available for logic inputs are terminals 5 to 16 inclusive, with term 4 also being
available for TGC modules. The CGC module uses terminal 4 for the Mains CB closed signal.
Enable Control via RS485 Comms menu 417

** This function permits the switching of selected input functions via the User RS485
communications. The User RS485 communications is a system option.
Remote Fault Reset menu 418

Provides for the reset of the Si-TEC Xtend alarm faults from a remote point, besides the on-board
reset key on the keyboard.
Rated Speed menu 419

This logic input is required to be "High" for the engine-generator to run at the preset operating
speed. With this input at “Low”, the set will remain at the preset idle speed. An application could be
to confirm ‘oil pressure’ prior to raising the engine speed, or for engine maintenance and testing
purposes.
Over Speed Test Select menu 420

When set “High”, this control function provides for an over speed test procedure only when the
engine-generator is off-line. The unit will ramp to the preset overspeed reference, which is set
slightly higher than the speed (RPM) when the overspeed trip protection will operate. Consequently
with the overspeed protection operating correctly, the overspeed reference setting will not be
attained. Should the overspeed trip test fail, the engine-generator will be controlled by the
overspeed reference. De-energising this input function would then place the generator into “cool
down” mode.
Fast Rate menu 421

If this input is “High” during starting, the fast rate mode is initiated. This mode bypasses the timed
periods of idle and warm up, and a more rapid idle to operating speed ramp rate will result.
Sequence Hold menu 422

Provided the engine-generator is up to operating (rated) speed, the control sequence will "halt" at
that stage when ”Sequence Hold” is “High”. This input has no effect during starting, at idle speed or
while the engine is ramping to the operating speed.
Typical uses and operations of the "Sequence Hold" input are:
1) If activated during warm up or while synchronising, then phase and voltage matching will cease,
and frequency and voltage are controlled to preset operating frequency and voltage.
2) If activated while the generator is on line, the frequency and voltage are controlled to maintain
real and reactive loads as at the time the input was activated.
3) For generators operating in phase lock but do not parallel with other systems, the input can be
used as a phase lock disable. If the input is “Low”, the generator will phase lock, if “High” it will not
phase lock.
The "Sequence Hold" status of the logic outputs is released should input 1 (Enable Run) go “Low”.
Pre-heat Complete (pre crank) menu 423

The pre-heat time function provides for the “glow plug” pre-heat cycle. This is terminated upon
completion of the pre-heat set time, or by switching the Pre-Heat Complete function “High”. Should
the pre-heat cycle not be required (eg. for gas engines), set this input function to ‘always ON’ (i.e.
the pre-heat is set to be already completed and therefore will not function). A relay output is
required to be configured to switch the “glow plugs”, allowing the pre-heat cycle to be initiated. In
addition, while the pre-heat time may be set through menu 210 (Set Up and Commissioning
Manual), an optional “Pre-heat between crank attempts” (menu 211) may be enabled.
32
Synchronise Inhibit menu 424
Disables the CB close signal when this function is switched high during the generator synchronising
operation.
Enable Load Share Select - For TGC and CGC modules: menu 425
Set function to always ON, unless there is a requirement to switch the generator out of load sharing
mode (eg. bus-coupler opened, connecting this generator to other generators). Disables control
from a GSM master module, reverting to the generators own set points. This should only be
“disabled” (switched “Low”) when connected to the utility grid.
kWatt De-Rate menu 426

If this input is “High” the kWatt de-rating preset value of the generator is used for load sharing
calculations. A common use for this feature is to de-rate the output on a pre-alarm over
temperature, enabling time for an additional set be started and switched on line prior to shutdown.
The preset value may also be set higher than the rated kWatt, providing a proportional increase in
load when this input is activated.
Base Load (1 and 2) menus 427 and 428

This function facilitates the operation at two different base load settings for both kWatt and P.F.
When this function is switched “High” the generator will operate as a base load machine. The kWatt
reference being the preset menu item ”Base Load kW”, or if configured a 4-20mA kWatt reference.
Base Load 1 is a preset menu function only, whereas Base Load 2 may be preset or a 4-20 mA
reference. The kWatt control priority levels are: (1) Base Load 1 set point, (2) Base Load 2 set
point, (3) Master (GSM) reference set point, (4) Grid Paralleled kWatt set point {“1” highest and “4”
lowest}.
st nd
Gen Group 1 to 4 – (1 Bit and 2 Bit) menus 429 and 430
** The grouping control is an option of the Si-TEC Xtend modules. This group control provides for
the load sharing of generators into 4 different groups. Suited for applications where bus couplers,
feeders etc. can separate the generators into different groups. The “Group Control” provides for the
load sharing and kVAr sharing of such “split groups” without switching the Si-TEC LAN
communications. The switching of the group input functions changes the group for this generator.
The two bits switch the group control in a matrix as follows.
Bit 1 Low, Bit 2 Low = Group 0
Bit 1 High, Bit 2 Low = Group 1
Bit 1 Low, Bit 2 High = Group 2
Bit 1 High, Bit 2 High = Group 3
Main Bus - Re-Sync to Grid - This is a CGC control function only menu 431
Energise input to re-synchronise to the utility grid (may go low after main CB closed).
Operative only when gen CB (input 3) closed and mains CB (input 4) open.
Used where a single generator and its connected load are required to re-synchronise back to the
utility grid. The close CB relay output of the Si-TEC Xtend module being re-directed from the
generator CB to the mains incoming CB. An external change-over relay is required to switch the CB
closing signals.
Enable Minimum Import Select - This is a CGC control function only menu 432
This control function provides for a kWatt limiting control on the incoming supply. For a single CGC
controlled generator, a kWatt bi-directional transducer can be installed measuring the incoming
supply from the utility grid. A 4-20mA signal from this transducer provides an input to a Si-TEC
Xtend 4-20mA analog input. The kWatt minimum import set point can be set negative or positive to
limit the kWatt export or to provide minimum import. The logic input function requires to be “High” to
activate this function. This input could also be set to ‘always ON’, which maintains the limiting
control function.
Sum Import Sensors Select - This is a CGC control function only menu 433
Where the “Enable Minimum Import” function above is utilised, the “Sum Import Sensors” provides
for the addition of the two import/export transducers on paralleled incoming supplies. The kWatt
transducers being two 4-20 mA inputs into the Si-TEC Xtend module.
33
Manual Speed Increase menu 434
Increases the speed when in the manual mode (Auto is “Low”). Refer to the “Auto” input
description. This adjustment will also increase the kWatts (real power) when the generator CB
(input 3) is closed.
Manual Speed Decrease menu 435

Decreases the speed when in the manual mode (Auto is “Low”). This adjustment will also decrease
the kWatts (real power) when the generator CB (input 3) is closed.
Manual Voltage Increase menu 436

Increases the alternator voltage bias when in the manual mode (Auto is “Low”). Refer to the “Auto”
input function. This adjustment will also increase the kVArs (reactive power) when the generator CB
(input 3) is closed.
Manual Voltage Decrease menu 437

Decreases the alternator voltage bias when in the manual mode (Auto is “Low”). This adjustment
will also decrease the kVArs (reactive power) when the generator CB (input 3) is closed.
“Auto” Input menu 438

This input is to be “High” (energised) for automatic operation and “Low” for manual operation. The
manual/auto refers to the Si-TEC Xtend control mode and does not relate to the external control
system automatic / manual operations. For all normal operations this input should be energised,
allowing the diesel or gas engine-generator to function in the automatic start sequence and load
sharing/control mode. Hence, the preset configuration for the “Auto” input logic function is always
ON. It should be noted that the Si-TEC Xtend manual mode function is intended only as a
“technicians tool” and not as the normal mode of operation.
“Auto” Input – “Low” (Manual Mode)

When the “Auto” input is “Low” the manual operation is activated, and the preset actuator position
droop or kW droop is introduced. In the manual mode the engine-generator’s speed/kWatts and
Volts/kVArs will remain at the level prior to switching to manual. The logic inputs for Volts (kVArs)
adjust and for speed (kWatts) adjust are only functional as raise/lower inputs while in the manual
mode.
If switched to the manual mode while the circuit breaker is open, the speed and voltage of the
generator remain at the levels prior to switching. If switched when the generator circuit breaker is
closed, then the generator kWatt and kVAr remain at the levels prior to switching. The exception
being that when input 1 (Enable Run) goes “Low”, the relay outputs for the generator CB and fuel
solenoid open immediately, resulting in any immediate shutdown of the engine-generator unit.
Under manual control the generator speed control will operate under “droop” mode. The droop can
be referenced to kWatt loading or Actuator position. Refer to “Manual Control Sub Menu” - “Select
Droop Mode” (menu item 402 in the “Set Up and Commissioning Manual”).
The automatic adjustment of load as described below under "Sequence Hold", does not function in
the manual mode.
Note: In the manual mode the system mode state does not change, except on start up where the
initial hold state is in the synchronising mode (CB closure in inhibited). In addition, the engine-
generator will not go through the sequence shutdown if it is in manual mode.
“Auto” Input – “High” (Automatic Mode)

When the “Auto” input is “High” the automatic operation is activated. If the engine-generator is at
operating speed, automatic operation ensures that the generator commences synchronisation with
the load bus and issues a “Close CB” relay output command to parallel the unit with the load bus.
This condition is possible only if the “Start Seq.” input (input 2) is “High”, and both “Sequence Hold”
and “Synchronise Inhibit” inputs are “Low” or configured to always OFF.
Upon the generator CB closure (ie input 3 is “High”), the active power (kWatt) and the reactive
power (kVAr) are automatically controlled to maintain a balance between all sets on line. The kVAr
34
is controlled via the motor operated potentiometer or analog AVR bias trimming and kWatt load via
the actuator.
In addition if there is no master module in the system, engine speed and alternator voltage are
controlled to the average of each operational unit’s preset frequency and Volts. If a master module
is enabled on the Si-TEC LAN communications link, then it sets the bus frequency and voltage
reference values.
Note: The GSM master module provides a higher level of long term frequency accuracy including
fine error correction. It further provides true RMS bus voltage detection, rather than the average
voltage detection calibrated for sine wave RMS. The logic inputs for raising / lowering of speed and
Volts are rendered inoperative whilst in the automatic mode.
Relay Outputs – Allocate a Function to a Relay – Sub Menu
Relay outputs may be allocated as both control and alarm functions. Select the required relay then
use the and keys to scroll through the control and alarm selection. Press the ‘Store’ key to set
that selection.
The control and alarm functions are described in detail in the “Design and Installation Manual”
Relay Output RL-1 Select a Function menu 451

Control functions include:

Fuel solenoid
Cranking Engine
At Running Speed
Raise Voltage
Lower Voltage
Engine glow plug pre heat
kWatt level switch (1) and (2)
Generator CB closure (fixed output refer above)
Trip Generator CB
Speed Switches (1) and (2)
KW Hour Pulse
KVAr Hour Pulse
All alarm functions can be individually set for:

i) Disabled ii) Enabled or iii) to Trip the generator CB :
this selection is displayed as [D/E/T] in the ‘RELAY OUTPUTS / ALARMS “ Menu
Alarm functions include:

Reverse Power
High kWatt
Phase Unbalance
High kVAr
Reverse kVAr (under excitation)
Under Frequency
Over Frequency
Under Voltage
Over Voltage
Combined alarms (1) and (2)
Latched alarms (1) and (2)
DC Supply Volts Low
35
Sync - Failure
Speed Sensor Failure
Import kWatt High (CGC only)
Export kWatt High (CGC only)
Vector disturbance (loss of utility supply whilst connected to mains – CGC only)
## Note: AVR Motorised Operated Potentiometer (Raise Volts – Lower Volts)

Use one relay for raising the voltage and one relay for lowering of the voltage. This is only required
if a motor operated potentiometer is utilised or if only logic inputs are used by the AVR for biasing.
kWh / kVAr METER – Pulsed Output - Sub Menu
kWatt Hour per Pulse menu 481

Sets the kWatt Hours between output pulsed output. Adjustable from 1 to 10,000 kWH.
kWatt Hour pulse on time menu 482

Sets the on time of the pulse for kWH. Adjustable from 0.1 to 5.0 seconds.
kVAr Hour per Pulse menu 483

Sets the kVAr Hours between output pulsed output. Adjustable from 1 to 10,000 kVArH.
kVAr Hour pulse on time menu 484

Sets the on time of the pulse for kVAr. Adjustable from 0.1 to 5.0 seconds
Analog Inputs – Allocate to Input – Sub Menu
Analog Inputs are available to provide references and control inputs. Each of the analog input
functions has three associated menu items.
The “Allocate to a Source” provides for selection of the input “channel” (ie. AI-1, AI-2, AI-3, Modbus
Communications, etc).
The “Min Reference” is the value represented by the minimum range of the input source (ie. 4mA
for a 4-20mA input, 0 for a communicated value, etc).
The “Max Reference” is the value represented by the maximum range of the input source (ie. 20mA
for a 4-20mA input, “High Modbus Ref.Value” for a communicated value, etc).
The reference input values may be assigned so that the maximum input value may be either
positive or negative, and similarly for the minimum input value. This allows greater flexibility with the
selection of transducers.
The following examples are provide:

st
1 Import kW Sensor – Allocate a source = AI-2 (a 4 to 20mA input)
4mA min reference -1015 | +1500 | +3855
20mA max reference +2516 | + 200 | - 800
st
1 Import kW Sensor – Allocate a source = “Modbus Communication”
0 min reference -1015 | +1500 | +3855
for 12 bit 4095 max reference +2516 | + 200 | - 800
for 14 bit 16383 max reference +15000 | + 200 | - 800
kWatt Control – Allocate a source = AI-1 (a 4 to 20mA input)

4mA min reference 0 | +100 | +1200
20mA max reference +1200 | +1200 | +100
36
High Modbus Ref. Value menu 491
** The menu item “High Modbus Ref. Value” provides for the setting of decimal values representing
the ‘Maximum Reference’ or 100% value for that input function (in lieu of the analog 4-20mA). For
example if the maximum (100%) communicated value was a 12 bit number this would be set at
4095; and for a 16 bit capacity, set at 65535. The Si-TEC Xtend module then scales the input value
for the input function references.
Temperature (RTD) (AI-4) Source menu 492

This sets the source for the temperature sensor input.
RTD AI-4 Zero Offset Comp menu 493

This provides an ‘Offset’ for a RTD sensor to the input AI-4. This is used to compensate for cable
resistance and other factors affecting the accuracy of the sensor measurement.
kWatt Control –
This sets the kWatt reference for a generator paralleled to the supply grid operating without a
master Si-TEC Xtend (GSM) module, and for external kWatt base load reference control.
kWatt Control Allocate to a Source menu 497

kWatt Control kW @ Min Reference menu 498
kWatt Control kW @ Max Reference menu 499
kWatt Limit Control –

This is used to provide a limiting point for the generator kWatt. A kWatt limit has priority over all
other kWatt references, whether by a master module, a preset reference or a 4-20 mA kWatt input.
kWatt Limit Allocate to a Source menu 500

kWatt Limit kW @ Min Reference menu 501
kWatt Limit kW @ Max Reference menu 502
kVAr Control –
This sets the kVAr reference for a generator paralleled to the supply grid operating without a master
Si-TEC Xtend (GSM) module, and for external kVAr reference control where a variable 4-20 mA
reference is required over the preset kVAr references.
kVAr Control (Grid) Allocate to a source menu 503

kVAr Control (Grid) kVAr @ Min Reference menu 504
kVAr Control (Grid) kVAr @ Max Reference menu 505
PF Control –
This sets the Power Factor (PF) reference for a generator paralleled to the supply grid operating
without a master Si-TEC Xtend (GSM) module, and for external PF reference control where a
variable 4-20 mA reference is required over the preset PF references.
PF Control (Grid) Allocate to a source menu 506

PF Control (Grid) PF @ Min Reference menu 507
PF Control (Grid) PF @ Max Reference menu 508
Warm Up Speed –
This is the warm up speed of an engine prior to synchronising, which may be varied externally.
Warm Up Speed Allocate to a Source menu 509

Warm Up Speed RPM @ Min Reference menu 510
Warm Up Speed RPM @ Max Reference menu 511
st
1 Import kWatt – (for CGC modules Only)
This 4-20mA input is for a bi-directional kWatt transducer measuring the load from the supply grid.
The input signal representing Import/Export kWatt provides for a Minimum Import (or Maximum
Export) kWatt level.
37
st
1 Import kW Sensor Allocate to a Source menu 512
st
1 Import kW Sensor kW @ Min Reference menu 513
st
1 Import kW Sensor kW @ Max Reference menu 514
nd
2 Import kWatt – (for CGC modules Only)
This 4-20mA input is a secondary bi-directional Import/Export kWatt transducer. For paralleled
incoming supplies the two incoming feeders may be summed to provide a total Import/Export kWatt
level for limit control of Minimum Import (or Maximum Export) kWatt level.
nd
2 Import kW Sensor Allocate to a Source menu 515
nd
2 Import kW Sensor kW @ Min Reference menu 516
nd
2 Import kW Sensor kW @ Max Reference menu 517
Minimum Import kWatt Set point – (for CGC modules Only)

This 4-20mA input provides for the generated power to be referenced to maintain a variable
Import/Export kWatt level. A preset value may be used if a variable reference is not required. To
operate this function a bi-directional kWatt transducer(s) on the incoming supply must be installed.
Min Import kW Setpoint Allocate to a Source menu 518

Min Import kW Setpoint kW @ Min Reference menu 519
Min Import kW Setpoint kW @ Max Reference menu 520
Analog Outputs – Assign Data Type –Sub Menu
Three 4-20mA outputs are provided on the Si-TEC Xtend module with additional 4-20mA outputs
available on the Can Bus extension module (**).
The outputs may be selected to represent the following data types:

Engine Speed
Actuator Position %
Generated kWatt
Generated kVAr (provides for negative values)
Generator Power Factor
kWatt Set Point
In configuring the 4-20mA outputs first assign a data type to the output, then set the value to
represent 4mA and then set the value to represent 20mA. These settings would correspond to the
scaling of instrument or device that the 4-20 mA output is driving into.
Generator Power Factor – range is adjustable in units NOT in power factor

4mA = preset value (in units - typically 0) : 0 = 0.50 PF leading
20mA = preset value (in units - typically 10000) : 10000 = 0.50 PF lagging
The scaling of the power factor meter must be linear
The Si-TEC Xtend module provides for adjustable and reverse range scaling of the power factor
meter.
Examples:
Meter Scaling set preset unit values to
4mA - 20mA 4mA @ 20mA @
0.50 lead 0.50 lag 0 10000
0.70 lead 0.70 lag 2000 8000
0.50 lag 0.50 lead 10000 0
0.80 lead 0.40 lag 3000 11000
0.30 lead 0.20 lag - 2000 13000
Analog Output AO-1 Assign Data Type menu 551

Analog Output AO-1 4mA = menu 552
38

39
3.9 RELAY OUTPUTS / ALARMS – Switch Set Points – Main Menu
The following set points provide for the triggering of the alarm/control functions.
The selection “[D/E/T]” (abbreviated [Disable / Enable / Trip the generator CB].
When an alarm is Disabled that alarm will not even be displayed if the set points are exceeded.
When an alarm is Enabled that alarm will be displayed and be active in the alarming system.
If the selection is set to Trip the generator CB, the Si-TEC Xtend module will display the alarm and
will also carry out a Generator CB trip function via the allocated relay output or a “Combined Alarm”
output (refer to Logic Outputs – Allocate a Function to a Relay, page 35-36).
The alarm functions should be interlocked with the control system to provide the desired operational
requirements. For example during the operation of “Reverse Power”, the Si-TEC Xtend module may
trip the generator CB. However, should the alarm:
a) Perform an immediate shutdown of the engine without a cool down period

Or [de-energising Si-TEC Xtend logic input 1]
b) Provide a cool down sequence before a shutdown of the engine.
Or [de-energising Si-TEC Xtend logic input 2]
c) Permit the generator to conduct a re-synchronising function.
[logic inputs 1 and 2 both remain energised]
this would depend on the external control logic and protection. If a “Combined Alarm” output is
used, then the combined latched alarm may be reset either from the Si-TEC Xtend module keypad
or via a logic input assigned to perform the “Remote Fault Reset” function.
Speed (RPM) – Set Points – Sub Menu
Engine “Running” Indication RPM menu 592

Engine “Running” Indication Delay menu 593
Speed Switch No1 Close at RPM menu 594

Speed Switch No1 Delay before Action menu 595
Speed Switch No2 Close at RPM menu 596

Speed Switch No2 Delay before Action menu 597
Speed Deviation From Set-Point (Alarm) menu 598

Speed Deviation Delay before Action menu 599
Speed Deviation Trip Gen CB [D/E/T] menu 600
Volts / Frequency – Set Points – Sub Menu
Gen Voltage – Low in % of Rated Voltage menu 606

Gen Voltage – Low Delay before Action menu 607
Gen Voltage – Low Trip Gen CB [D/E/T] menu 608
Gen Voltage – High in % of Rated Voltage menu 609

Gen Voltage – High Delay before Action menu 610
Gen Voltage – High Trip Gen CB [D/E/T] menu 611
Freq. – Low (Gen) at % of Rated Freq. menu 612

Freq. – Low (Gen) Delay before Action menu 613
Freq. – Low (Gen) Trip Gen CB [D/E/T] menu 614
Freq. – High (Gen) at % of Rated Freq. menu 615

Freq. – High (Gen) Delay before Action menu 616
Freq. – High (Gen) Trip Gen CB [D/E/T] menu 617
40
kWatt – Set Points – Sub Menu
kWatt Reverse Power in % of Rated kWatt menu 626

kWatt Reverse Power Delay before Action menu 627
kWatt Reverse Power Trip Gen CB [D/E/T] menu 628
kWatt - High in % of Rated kWatt menu 629

kWatt - High Delay before Action menu 630
kWatt - High Trip Gen CB [D/E/T] menu 631
kWatt 3 phase Unbalance in % of Rated kWatt menu 632

kWatt 3 phase Unbalance Delay before Action menu 633
kWatt 3 phase Trip Gen CB [D/E/T] menu 634
kWatt Switch No 1 ON in % of Rated kWatt menu 635

kWatt Switch No 1 ON Delay before Action menu 636
kWatt Switch No 1 OFF in % of Rated kWatt menu 637
kWatt Switch No 1 OFF Delay before Action menu 638
kWatt Switch No 2 ON in % of Rated kWatt menu 639

kWatt Switch No 2 ON Delay before Action menu 640
kWatt Switch No 2 OFF in % of Rated kWatt menu 641
kWatt Switch No 2 OFF Delay before Action menu 642
kVAr – Set Points – Sub Menu
kVAr - High in % of Rated kWatt menu 651

kVAr - High Delay before Action menu 652
kVAr - High Trip Gen CB [D/E/T] menu 653
Leading (reverse) kVAr / Lead PF in % of Rated kVAr menu 654

Leading (reverse) kVAr / Lead PF Delay before Action menu 655
Leading (reverse) kVAr / Lead PF Trip Gen CB [D/E/T] menu 656
Group Switch Points – ‘together” to Form Combined Alarms – Sub Menu
Latched Combined Alarm No 1 - Bit Count Value menu 681

Latched Combined Alarm No 2 - Bit Count Value menu 682
Combined Alarm No 1 Bit Count Value menu 683
Combined Alarm No 2 Bit Count Value menu 684
Miscellaneous Set Points – Sub Menu
Fail to Synchronise Delay before Action menu 691

DC Supply Volt Low 18.0 Vdc Suggested menu 692
DC Supply Volt Low Delay before Action menu 693
Paralleled to Mains Switch Point – Sub Menu
Vector Disturbance –Switch Point Limits – Sub Menu
Loss of 3 Phase – Phase Angle Shift menu 711

Loss of 3 Phase – Trip Gen CB [D/E/T] menu 712
Phase Unbalanced – in Percent menu 713
Phase Unbalanced – Delay before Action menu 714
Phase Unbalanced – Trip Gen CB [D/E/T] menu 715
41
4 CONTROL NOTES
## THIS IS A CONTROL DEVICE AND IS NOT TO BE USED FOR ENGINE SPEED

PROTECTION. SEPARATE INDEPENDENT SAFETY SHUTDOWN DEVICES MUST BE
USED FOR OVERSPEED PROTECTION.
## The internal Si-TEC Xtend alarm functions may be selected to operate the module's CB trip
output and/or to switch an output relay. Internal tripping of the generator CB should be
interfaced to latching circuit(s) to inhibit generator control under such alarm conditions. This
provides flexibility to suit the required control operation. The alarm relay outputs are only
operative at the “Alarm State” and do not latch within the module. All latching for alarm
indication and/or control interfacing should be conducted external to the module.
## Upon the operation of various alarms it is desirable to "advise" the Si-TEC Xtend module of
a change to the required control state, by de-energising the relative logic input(s). For
example if reverse power is sensed, internally or externally trip the CB, de-energise and
latch out the Start Seq. input (input 2), which then places the module into the cool down
operation mode. Without de-energising input 2 the module is still instructed to operate
normally. In this situation the control realises that the Gen CB input (logic input 3) is de-
energised, and with input 2 energised the mode of operation would be to re-synchronise
the generator with the bus. By de-energising input 2, the mode changes to the normal "off
line" sequence of a “cool down” period followed by a controlled shutdown operation.
Likewise should an external "Ground Fault" or "Oil Pressure Failure" be sensed, it would be
advisable to de-energise and latch out the Enable Run input (input 1) for immediate
shutdown. The shutdown control modes (whether by input 1 or 2) operates the CB trip/open
signal as part of the shutdown procedure.
## Refer to the following sequence operation of logic inputs 1 and 2 (section 4.2, page 44).
## CB close relay contacts momentary close when generator is synchronised signalling for the
Circuit Breaker to close. The relay is de-energised should the generator move out of
synchronisation and/or if the generator CB auxiliary input (via input 3) signals that the
circuit breaker has closed (after a 1-second delay to prevent "pumping" of the CB). This
relay operates as a maintained output if a CB trip relay is not selected.
4.1 Logic Inputs
## The inputs may be powered from an external 24Vdc supply, provided that the grounding is
common. A separate common terminal (terminal 0) is provided.
The logic input voltage may range from 10V to 32Vdc however 24Vdc is recommended.
Various logic inputs may be configured to suit the user application. Refer to the Menu
Functions and settings for further logic input options and selection. The following list is a
description of the logic input control functions and these functions allocated to the listed
input terminals.
It should be noted that more than one input control function may be assigned to a single
common logic input. Input functions may be set to:“0” or “always OFF”, “1” or ”always ON”,
or allocated to a switched logic input.
42
4.2 Fixed logic Inputs
Enable Run - Input 1 (terminal 1)

## Logic Input 1 is required to be “High” (energised) for the engine-generator unit to run. De-
energising input 1 will immediately trip the generator circuit breaker, drive the actuator to zero fuel
and de-energise the fuel solenoid output.
Under manual operation, input 1 requires to be de-energised for shutdown operation. Input 1 should
be energised when conducting actuator test functions (I/O Test Functions).
The engine "fault shutdown" or “emergency shutdown” devices should be interlocked with this input
and externally latched off.
Start Sequence - Input 2 (terminal 2)

This logic input initiates the normal starting and stopping of the generator. The normal sequence of
operation is described below. Input 2 is required to be "High" in order for the user select “Fast Rate”
and “Sequence Hold” logic inputs to function.
Upon input 2 going "High" (provided input 1 is "High"):
1 Pre-heat is carried out (for diesel engines only) via the “Engine Glow Plug Pre Heat” relay
output.
2 Gas purge cycle is activated (for gas engines only). The actuator opens (increase position) to
set the purge position. Purging is conducted for the time and the number of purge cranks. The
crank wait time is used between purge cycles.
3 The “Fuel Solenoid” relay output is energised on completion of the purge cycle, as the engine
passes into the first cranking cycle and when a MPU input pulse is measured. The transition
from purge to crank occurs without a wait time.
4 Governor actuator is positioned for starting fuel requirements (Start Fuel Limit position).
5 Cranking cycle is activated. (with adjustable on / off times and crank attempts)
6 The “Cranking Engine” relay output is energised.
7 Crank cut out occurs when the engine RPM is above the cranking speed.
8 Engine idles (at idle speed) for a preset time or until Rated Speed function is “high”, then ramps
to the operating (rated) speed (ramp rates are adjustable to suit all prime mover applications).
9 Engine warms up for a further preset time (also see “fast rate”).
10 System synchronises the incoming generator to the main bus (or grid) after matching
frequency, phase angle and voltage. Phase rotation is further checked before permitting the
closure of the "Close CB" output terminals 17 & 18 (fixed designated relay output).
11 kWatts and kVArs are ramped at a preset rate (e.g. 8% per sec) until load is shared with the
other sets on the bus, or if the unit load reaches it’s set point (base load) reference.
Upon input 2 going "Low" (removal of "Start Seq." signal):
1 Generator load ramps down at the preset rate (e.g. 3% per sec). kWatts and kVArs must
unload below the preset levels prior to the normal switching off line (opening the CB). Should
unloading not occur within a preset maximum time, the switching off line will occur regardless of
the kWatt/kVAr levels.
2 The generator runs at rated speed for the preset “cool down” time.
3 Following the cool down period the actuator drives to zero fuel and the fuel solenoid output is
de-energised. The engine-generator is then fully shutdown, and is ready for another start
sequence.
4 For gas engines, a post purge cycle will shut off the fuel solenoid and open the actuator (not
exceeding the rated speed) until the engine loses the MPU input.
5 Removal of the signal to input 2 resets the controller following any alarm condition (e.g.
Reverse Power).
## Note: Latch out input 2 if the CB is tripped under a fault condition. This will "advise" the Si-TEC
Xtend module of a sequence stop requirement and prevent any re-synchronising mode
occurring. Switch input 1 to “Low” for an immediate shutdown.
43
Generator CB Closed - Input 3 (terminal 3)
## Input 3 is to be “High” (energised) when the generator circuit breaker is closed. This input is
typically derived from the circuit breaker auxiliary contacts. On receiving a “High” signal the Si-TEC
Xtend controller performs the kWatt and kVAr sharing functions. Check this input status should the
generator not be taking load. Faulty auxiliary contacts of the generator CB will affect the
requirement to operate under proper load control and load sharing conditions.
Mains CB Closed - Input 4 (terminal 4 - fixed for CGC modules only)

## Input 4 is to be “High” (energised) when the generator is paralleled to the supply authority
mains. With this input being "High" and the Gen CB closed (input 3), the Si-TEC Xtend controller
will operate under the control of the Paralleled P.I.D. settings. This input (4) is typically energised
from the mains incoming CB auxiliary. There should be additional switching between the generator
CB and the main CB it is necessary to interlock the “switched” devices with this logic input.
4.3 Combined Alarms
To select the combination of alarm functions for the 4 combined alarm outputs the value has to be
set representing the decimal value of the bit representation.
Bit Value Alarm

0 1 Reverse Power
1 2 High kWatt
2 4 Reverse kVAr
3 8 High kVAr
4 16 Under Frequency
5 32 Over Frequency
6 64 Under Voltage
7 128 Over Voltage
8 256 Import kWatt High **
9 512 Export kWatt High
10 1024 Vector Phase Unbalance
11 2048 Phase Unbalance
12 4096 Vector 3-Phase Loss
13 8192 Phase Angle Shift
14 16384 High Current **
15 32768 Alternator Temperature **
16 65536 Low Actuator Feedback
17 131072 High Actuator Feedback
18 262144 DC Supply – Low Volts
19 524288 MPU Failure (engine STOP)
20 1048576 Synchronising Failure
21 2097152 Start Failure
22 4194304 Speed Deviation
23 8388608 Variable Error
24 16777216 MPU 1 Fail
25 33554432 MPU 2 Fail
For example a selection of Electrical Alarms the value needs to be:-

Hi kVAr 8
Hi kWatt 2
Rev kVAr 4
Rev kWatt 1
Over Voltage 128
Over Frequency 32
Unbalanced kW 2048
----------
Sum 2223 : hence set the “Code” to 2223
44
For example to combine the synchronising failure and the start failure then:
Synchronising Failure 1048576
Start Failure 2097152
--------------
Sum 3145728 : hence set the “Code” to 3145728
Any combination may be set for each of the two Combined Alarms, and each of the Latched
Combined Alarms.
The “Windows” based “Si-TEC pcConfigure” software provides an option for “ticking” of the required
alarms, to allow the value to be calculated.
45
5 PID CONTROLS
The Si-TEC Xtend governor/generator control modules have eight PID controls:
5 speed control PID settings
1 kWatt control
1 kVAr/PF control
1 Voltage/AVR control
5.1 Speed Control - Multiple Dynamics
NOTE: In the following description "Paralleled" refers to being paralleled to the supply grid. Such
references relate only to the Co-Generation Control (CGC) modules.
5.2 P.I.D. Definitions
PROPORTIONAL
Proportional is the amount of correction (gain) factor required for a given speed/load error.
Increasing the preset Proportional value increases the sensitivity of response to an error.
INTEGRAL
Integral is the time constant (stability) for the proportional correction.
Increasing the preset Integral value will decrease the time constant (stability) or reset time.
DERIVATIVE
Derivative is the amount of correction in relation to the rate of change of speed/load error.
Increasing the preset Derivative value will increase the amount of actuator compensation.
When the generator CB is open, the Si-TEC Xtend TGC and CGC dynamics are controlled by the
Idle speed PID and Rated speed PID. At “Idle Speed” or lower, the Idle speed PID settings will
assume control. At “Rated Speed” and above, the Rated speed PID values assume control. In
between, linearly interpolated values between the Idle and Rated settings are used.
Once the generator CB is closed, the PID control settings are from:
• Paralleled PID if the Mains CB input (input 4) is active. (CGC modules only) OR
• Rated speed PID if “Multi Point On-Load PIDs" have not been enabled OR
• If they have been enabled, the values are linearly interpolated from rated speed (0%kW)
PID, Mid-point kW PID, and 100% kW PID, with the interpolation being controlled by the
kW load on the generator. The mid-point kW % is programmable from the display, which
allows flexible control as shown in the examples below. Note that the interpolation is done
separately for each of the proportional, integral and derivative terms.
Notes: At kWatt > 100% of the rated kW, the 100% kW PID will remain in control.
At negative kWatts, the Rated speed PID will assume control.
For most applications it is not necessary have the "Multi Point On-Load" PID operative.
When the "Enable MULTI Point On-Load Speed PIDs” is set to "NO" the unit is controlled by the
Rated speed PID when off-line or connected to an islanded load bus, and from the Parallelled PID
when connected to the supply grid. The Multi Point PIDs are not active when the generator is
paralleled to the supply grid.
The Si-TEC Xtend supports a PC software program for the tuning of the Si-TEC Xtend governor
and generator control, providing accurate visual displays of performance, response, etc. on an IBM
/ Windows compatible personal computer. The PC is connected to the Si-TEC Xtend module via the
RS232. The “Si-TEC pcTune” software is available from Dawson Technology.
46
When tuning for optimum engine-generator dynamic response and stability, it is a normal practice
to go to the fuel system and "bump” the actuator/linkage to provide an error in order to evaluate the
recovery, stability etc. With the Si-TEC Xtend module a consistent error can be introduced upon
command, which provides 100 % accuracy in repeating the error.
Enable the “Access” key to make modifications to the set point values. Proceed to the PID
Adjustment – Speed Loop Response sub menu (menu items 232 to 244). The last items in the PID
menu are the "Actuator Disturbance BUMP Magnitude" (menu 242) and the " Actuator Disturbance
BUMP Duration" (menu 243). Set the “Magnitude” to say 15% - 20% and the “Duration” to 0.4 - 0.8
second. When the “BUMP” key is operated while in the PID menus, the actuator will drive down
15% for 0.4 seconds providing the set error. A menu item “Disturbance delay after pressing BUMP”
(menu 244) will delay the operation of the actuator BUMP for that set period.
This function may also be operated for synchronising and load control response.
5.3 Rated Proportional / Rated Integral / Rated Derivative
These are the P.I.D. settings controlling at the RATED SPEED.
The Proportional is the gain characteristic. Decrease the proportional setting to lower the sensitivity
response to speed change. If the Proportional is set too high a fast oscillation of speed would result
as over correction occurs. With the Proportional set too low, a sluggish response is experienced
along with a slow wandering of the speed about its reference.
The Integral is the stability factor (time constant) of the PID correction and is relative to the
Proportional. Increasing the Integral preset value decreases the time factor. A high setting of the
integral would create a slow oscillation of the engine speed. The Integral is tuned in conjunction
with the Proportional constant to obtain the optimum response, while maintaining a stable speed
control. Derivative values should be low for responsive engines and actuators (eg. 0 to 30). Higher
Derivative settings are necessary for Gas Engines and/or when driving Woodward Hydraulic
Actuators. Incorrect Derivative values may cause the actuator to jiggle.
5.4 Do Fast Response when out of % Band / Fast Response Proportional / Fast
Response Integral
Under the “PERFORMANCE ENHANCED – PID Adjustments

Fast Response % is the percentage of speed error when the fast response multipliers become
active. Nominally set multipliers to around 1.5, which then activates when the speed error exceeds
the “fast response %”.
Fast Response Proportional is the multiplying factor of the Rated Proportional Setting (the “Rated
P” constant) and operates when the speed error is beyond the preset value of the Fast Response
per cent setting (nominally set to 1.5). Increasing this multiplier will increase the proportional factor
during excessive speed errors.
The Fast Response Proportional value should be reduced if excessive actuator overshoot is
observed and if the Rated Proportional is optimally set. The Fast Response Proportional is also
operative during the synchronising mode.
The Fast Response Integral is the multiplying factor to the Rated Integral Setting and operates
when the speed error is beyond the setting of the Fast Response per cent. This is nominally set to
2.0. Increasing the preset value will increases the actuator integral response (reduce the time
constant).
Reduce the Fast Response Integral value if the actuator show instability and if the Rated Integral is
optimally set. The Fast Response Integral is also operative during the synchronising mode. The
Fast Response Integral Multiplier is typically set to around 4.0 for less responsive engines.
47
5.5 Multi Point On-Load PIDs (mid point and 100% load - kWatt)
This PID will function when the "Enable Multi Point On-Load PIDs" is set to "YES". The PID only
functions during the “Islanded Mode” operation and does not operate when the engine-generator is
paralleled to the supply grid.
For easily tunable engine-generator control dynamics, the "Enable Multi Point On-Load PIDs"
function may be set to "NO". The Si-TEC Xtend will ignore the preset PID settings of this sub menu.
Examples
Example 1: Non-linear fuel metering systems that are sensitive during intermediate loads.
Prop
Prop (Gain)
(Gain)
Mid point set to 50%
Idle Rated 0%=Rated Speed 100% Load
Speed On Load kWatt
Generator CB Open Generator CB Closed

(mains CB open)
Here, the Proportional (gain) is reduced at the mid point kWatt load. This may be applicable when a
non-linear actuator linkage is used, and which does not correctly compensate for the non-linear fuel
metering. This may occur on some Cummins Engines that are fitted with PT fuel pumps, where the
control is stable at low loads and high loads, but may be unstable during intermediate loads.
The mid point for the “Mid Point PIDs” may be set from 0% (kWatt load) to 100% (kWatt load) If set
at 0% load then the Mid Point PIDs are operative as soon as the generator CB is closed after the
generator has synchronised.
48
Example 2: Non-linear fuel metering systems that are sensitive at no load and low loads.
Prop
Prop (Gain)
(Gain)
Mid Point
set to 20%
Idle Rated 0%=Rated Speed 100% load
Speed On Load kWatt

(mains CB open)
This example requires a low Proportional (gain) during synchronising and at lower loads. The
Proportional is increased as the load increases. This application is suitable when the control
compensates for some non-linear fuel metering systems, which may be sensitive at no load and
lower loads.
Example 3: Enabled upon the closure of generator CB.
The Rated speed PID is in control during synchronising. With the Mid Point % set at 0%, the Mid
Point % PID is active when the generator CB closes and then interpolates to the 100% kW PID (full
load).
PID PID
Mid Point % set to 0%

(which overrides
the rated speed values)
Idle Rated 0% 100%
Speed On Load kWatts

(mains CB open)
If the Mid Point % is set to 0%, then synchronising is done through the Rated speed PID. When the
breaker closes, the control uses Mid Point % PID at no load (or -ve load!) and interpolates to the
100% PID at full load or higher kW loads. This PID option is useful for “difficult to control” engines,
allowing flexible proportional, integral and high derivative action for fast and accurate synchronising,
without degrading on-load performance.
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5.6 Menu Preset Items for the additional – Isolated and On Line - P.I.D. functions
Menu items are listed under "High Performance Menu".

The sub-menu heading is "ISOL ON-LOAD PID MENU"
Menu items are
Enable On-Load P.I.D. (menu 271) .................

100% kWatt Proportional (menu 272) (K) .................
100% kWatt Integral (menu 273) (K) .................
100% kWatt Derivative (menu 274) (K) .................
Mid Point % of Rated kWatt (menu 275) % .................
Mid % kWatt Proportional (menu 276) (K) .................
Mid % kWatt Integral (menu 277) (K) .................
Mid % kWatt Derivative (menu 278) (K) .................
The fast response proportional and integral multipliers remain functional when the “Isolated
On Line” Mid Point PIDs are enabled.
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6 OPERATION and SERVICE INFORMATION
6.1 Actuator – MPU – Linkage Adjustments
{Note: The following procedures are intended for Si-TEC Xtend controls that interface with
Heinzmann all electric actuators}
Check Actuator Drive and Feedback
The actuator drive and feedback may be checked only when the engine is stationary. Hence, this
test function should be carried out while the engine is shutdown. The actuator feedback adjustment
is preset within the Si-TEC Xtend control module.
To perform the test proceed to the “System Diagnostics and Functional Tests” main menu, scroll
(via the “Select Menu” key) to the “Actuator Test” sub menu, and then to “Set Actuator Position” (1
or 2) within this sub menu. Alternatively the user may proceed directly to menu 081 (Actuator
Position 1) or 082 (Actuator Position 2). The desired output position and the actual actuator position
(feedback) are both displayed (in %).
Pressing the “Bump” key will enable the actuator test. Adjusting the “Set Actuator Position” from 0
to 100% (by operating the + / - buttons on the keypad) will cause the actuator to drive from 0% to
100%. The feedback is on the display to the left side of the LCD screen.
Confirm that using the + button will increase the actuator position and feedback. It is necessary to
conduct a physical check of the actuator at forced minimum position (0%), maximum position
(100%), and 2 intermediate positions. This will verify the correct driving of the actuator including
direction, and will confirm correct feedback voltage signal. The feedback should match the output
position within a small percentage.
Allow for the actuator to drive hard against the minimum and maximum fuel positions, where with
correct stroking the actuator would not be able to physically achieve 0 or 100% due to the
mechanical stops. The minimum and maximum positions of 5% and 95% should be achieved with
the linkage correctly set.
The “Actuator” information button on the face of the Si-TEC Xtend module provides details of the
output to the actuator, actuator feedback, actuator current, and actuator dc supply voltage. The
“Auto Toggle Actuator Test” may also be conducted from this sub menu.
Linkage Adjustment
The length of the actuator lever should be such as to allow approximately 90% to 95% actuator
travel to move the fuel rack from the minimum position to its maximum fuel position. The maximum
fuel position should be at the 95% to 98% position. With the fuel rack at minimum position the
actuator should be at the 3% to 5% position. The linkage geometry should be adjusted to achieve
this actuator travel.
Magnetic Pick Up Adjustment (MPU)
The distance between the magnetic pick up and top of the teeth of the ring gear should be 0.5mm
to 0.8mm. (With the prime mover stationary, it is possible to screw the magnetic pick up on to the
top of the teeth and unscrew it for about 1/3 to 1/2 turn)
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Magnetic Pick Up (MPU) Signal
If operating correctly the engine RPM (speed) will be displayed on the default display while the
engine is cranking.
Proceed to the “System Diagnostics and Functional Tests” main menu, and scroll to the “Display
I/O States” sub menu. Scrolling through this sub menu will eventually display “MPU1 and MPU2 –
signals”, which displays the actual speed sensor signal value. Alternatively, the user may proceed
directly to Menu 050 to access this menu item.
The conventional form of verifying the MPU signal is as follows:

a) With a voltmeter measure the AC voltage at terminals 79 & 80 for MPU1 and 84 & 85 for MPU2.
The voltage should be more than 0.8 Vac at Cranking Speed and above 2.0 Vac at Rated Speed.
b) Using a frequency meter measure the terminals 79 & 80 for MPU1 and 84 & 85 for MPU2. The
frequency will be sensed above 200Hz (approximately). At the Rated speed of the engine, the MPU
frequency should measure between 1000 and 12,000 Hz.
The resistance of the MPU may vary depending on manufacturer specification, to suit different
applications. The MPU resistance range varies from 52Ω (low impedance) to 1100Ω (high
impedance). The MPU coil is isolated from the MPU body (> 100kΩ).
MPU and Feedback Cable Screening
Disconnect the MPU and Feedback screen (shield) connections to terminals 58, 82 & 87. The
screens should now be isolated (above 100kΩ) from ground, and the DC supply negative. All
screen connections should be wired to "ground" at one point ONLY to avoid ground loops. This
single connection is done at terminals 58, 82 & 87 for the respective cables. Verify the sheathing of
the screen cables to ensure that chaffing has not occurred, as this may cause momentary
secondary grounding of the shielding.
Reconnect the screen wires to terminals 58, 82 & 87.
Dedicated Magnetic Pick Up (MPU) for the Governing System
It is preferred that a dedicated MPU be used as a speed sensor for the governing system. Should
any other device be connected to this MPU, it is essential that the other device connections do not
cause the MPU input signal to be referenced to a positive DC voltage supply. If any of the devices
that are interfaced with the MPU inputs are linked to ground or positive DC voltage supply, it should
be ensured that that this does not conflict with the grounding of connections to terminals 80 and 85
within the Si-TEC Xtend module.
Proximity Switches
Speed sensing may also be possible through the use of proximity switches with either a NPN or
PNP open collector output. The default setting of the speed sensors is for MPU speed sensing.
However, it is possible for the speed sensors to be configured for proximity switch sensing through
internal jumper selection. Consult Dawson Technology if an application involving proximity switches
is required.
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6.2 Analog biasing for AVR Voltage Trimming
AVR Bias Output may be provided either via raise/lower relay outputs driving a MOP (motorised
operated potentiometer), or from an isolated analog DC voltage output.
To select the desired AVR bias output, proceed to the “AVR Control Method” menu item (menu
328). Set a value of “1” to select the Analog bias control or “0” for MOP bias control. This menu item
is within the “Voltage / AVR Control” sub menu.
The connections for the AVR Bias Output are:
MOP Bias: Raise Volts – User select relay output

Lower Volts – User select relay output
Analog Bias : Output (+) : Terminal 71

Return (-) : Terminal 72
Shield : Terminal 73
The isolated Analog DC voltage range may be adjusted from – 8.4V to + 8.4V by the set point
adjustments (menu items 334 and 335). Terminal 71 goes more positive with respect to terminal 72,
for an increased excitation in generator voltage output.
The tuning parameters affecting the Voltage / AVR control include:

Volts Proportional: Typically 35-50 (menu 326)
Volts Integral: Typically 50-70 (menu 327)
Manual Adj %/sec: The DC voltage bias rate (menu 407)
kVAr/PF Proportional: Typically 30-60 (menu 381)
kVAr/PF Integral: Typically 30-70 (menu 382)
The tuning procedure should be as follows, with the Voltage and kVAr Proportional and Integral
initially set at low values (the lower end of the typical value range):
(a) Ensure that the AVR has been set up for optimum voltage control, without the Si-TEC Xtend
AVR Bias Output.
(b) The Si-TEC Xtend Voltage Proportional and Integral should be tuned for stable voltage
control when the generator is off-line, and during voltage trimming for synchronisation. If the
Proportional and Integral values are too high, the AVR Bias Output correction will be too fast
when interacting with the AVR control. This is particularly noticeable when the generator
starts with a voltage overshoot.
(c) The Si-TEC Xtend kVAr/PF Proportional and Integral should be tuned for stable kVAr/PF
sharing with other generators, or kVAr/PF control when paralleled to the supply grid.
The kVAr limits are enforced when a generator is paralleled with the supply grid. The limits are
located in the kVAr/PF Control sub menu. Lagging kVArs are limited to rated kVAr calculated from
rated kWatt (menu 349) and rated P.F. (menu 384). Leading kVArs are limited to the value set in
the Leading kVAr Rating (menu 387).
A typical scenario where these limits may be utilised is when the supply grid voltage drifts beyond
the minimum/maximum limit voltage range set within the Si-TEC Xtend module. If the grid voltage
increases above the maximum limit, generator kVArs will be decreased due to the lower excitation
relative to the grid. If the kVArs decrease to the Lead kVAr limit, the Si-TEC Xtend control will
automatically adjust the generator excitation to hold the kVArs at the Lead kVar limit until the grid
voltage reduces. Similarly, if the grid voltage decreases below minimum Volts, kVAr will be
increased but only as far as the Lagging kVAr limit. This limit will be maintained until the grid
voltage increases.
On generator start up, the AVR Bias voltage level is set at the mid-point between the “minimum”
and “maximum” AVR Bias voltage settings. This holds the bias at a constant level until the “Voltage
Delay Before Action” (menu 331) delay time has elapsed. Until this biasing is actuated, the
alternator AVR is the only controlling device of the generator voltage. It should be noted that when
53
excitation commences after starting of the engine-generator, the initial voltage overshoot is
controlled by the AVR only. The Si-TEC Xtend “Voltage Control” PID assumes control thereafter.
Testing the AVR Bias effect on the alternator may be conducted when the generator CB (circuit
breaker) is open. For example, the generator is started and it is ensured that the Si-TEC Xtend is in
“Manual Mode” (i.e. “Auto” logic input is switched “low”). Using the “Force AVR Bias Output Test”
(menu 068), the required bias voltage level is set, and is followed by operating the “BUMP” key.
The generator Ph/N voltage may be observed in the lower left-hand corner of the Si-TEC Xtend
display screen. The test may also be carried out by using the “Si-TEC pcTune” software.
6.3 AVR Connections for Analog voltage trimming
AVK AVR
AVK terminal connections

Remote voltage trimming pot can be deleted from circuit.
Connect terminal S of AVR to Si-TEC Xtend terminal 72 (check polarity)
Connect terminal T of AVR to Si-TEC Xtend terminal 71 (check polarity)
Install a 1K ohm .6 watt resistor in series.
Basler AVR
Basler SR4A - SR8A terminal connections

Remote voltage trimming pot can be deleted from circuit.
Connect terminal 7 of AVR to Si-TEC Xtend terminal 72
Basler DECS terminal connections

Connect terminal of AVR to Si-TEC Xtend terminal 72
Connect terminal of AVR to Si-TEC Xtend terminal 71
Set the Basler DECS AVR to the desired reference voltage (eg. 415 Volts L-L)
No other potentiometer is required.
-1 Volt bias = -10%; 0 Volt bias = set voltage; +1 Volt bias = +10%
Caterpillar AVR
Caterpillar VR3-F terminal connections

Loop terminal 4 to terminal 9
Install 10 or 20 ohm 1 watt resistor between terminal 7 and terminal 9
Connect VR3 terminal 7 to Si-TEC Xtend terminal 71
Connect VR3 terminal 9 to Si-TEC Xtend terminal 72
Caterpillar DVR digital voltage regulator - terminal connections

Connect DVR terminal 7 to Si-TEC Xtend terminal 71
Connect DVR terminal 45 to Si-TEC Xtend terminal 72
Set DVR operational Volts at 420 volt Phase/Phase
No other potentiometers are required
0 Volt bias = -10%; + 2 Volt bias = set voltage; + 4 Volt bias = +10%
Kato AVR
Kato KCR-760
Connect AVR terminal R1 to Si-TEC Xtend terminal 71
Connect AVR terminal R2 to Si-TEC Xtend terminal 72
-4 Volt bias = -10%; 0 Volt bias = set voltage; + 4 Volt bias = +10%
External voltage trim pot is not utilised. Droop CT bridge link is hidden.
54
Leroy-Somer AVR
Leroy-Somer model R200 AVR terminal connections

Use terminal strip CN2 of the AVR (same terminal strip as the droop CT / Pot)
Connect terminal 6 of AVR to Si-TEC Xtend terminal 71 with series 4.7kOhm 1/2 watt
resistor.

Use terminal strip ____ of the AVR
Connect terminal __ of AVR to Si-TEC Xtend terminal 72
Connect terminal __ of AVR to Si-TEC Xtend terminal 71 with series 470 Ohm 1/2
watt resistor.

Use terminal strip ____ of the AVR
Connect terminal __ of AVR to Si-TEC Xtend terminal 72
Connect terminal __ of AVR to Si-TEC Xtend terminal 71 with series 470 Ohm 1/2
watt resistor.
Mecc Alte
Mecc Alte UVR6

Connect end volt trim terminal of AVR to Si-TEC Xtend terminal 72
Connect second from end volt trim terminal of AVR to Si-TEC Xtend terminal 71
Stamford AVR
Stamford MX 341 – MX 321 - SX 440 terminal connections

Loop terminal 1 to terminal 2 at the top of the AVR terminal strip (strip including x and xx )
Connect terminal A1 of vertical strip to Si-TEC Xtend terminal 72
Connect terminal A2 of vertical strip to Si-TEC Xtend terminal 71
NOTE:
When terminal 71 is more positive than terminal 72 the voltage is biased for increased excitation in
the generator voltage output.
For Positive voltage - increase excitation : Term 72 is Reference 0

Term 71 is Voltage Adjust
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6.4 Si-TEC Xtend CGC & GSM Vector Disturbance Relay
The vector disturbance relay allows rapid detection of the loss of mains supply by a paralleled Si-
TEC Xtend CGC (or GSM) unit. This is possible through the detection of a small change in the
generator voltage vector angle relative to the rotor mechanical position. For the vector angle
change to occur as a result of the loss of mains, the load on the generator must change by a
specific amount depending on the sensitivity setting. It is important to note that the operation of the
vector disturbance relay does not depend on frequency deviation or voltage amplitude variations.
The relay detects the vector disturbance within 2 cycles (40ms) of the mains (grid) separation,
allowing the generator connection to the mains to be tripped well before mains power system
automatic re-closure occurs (typically 200 ms to 5 secs after trip).
The one condition that the relay cannot detect is a mains separation when the load on the
generator side of the separation point is such that the generator set sees little or no load change.
In most power systems, this situation is unlikely. Should this occur, the vector disturbance relay
activates if and when the load attached to the generator changes sufficiently to cause the requisite
vector angle change .
The relay sensitivity setting is the vector angle change required to activate the relay, and is
adjustable via the Si-TEC Xtend keyboard from 1 degree to 15 degrees in 1 degree increments.
Approximate load changes required to cause vector disturbance magnitudes are listed below.
Vector Disturbance Degrees % Rated Load Change
1 5%
2 15%
5 35%
10 70%
The sensitivity adjustment is normally set to 5, which give the best compromise between a nuisance
tripping and detection coverage. The setting may be reduced to 1 degree in areas without ripple
voltage control systems, which at high amplitudes can cause apparent vector disturbances of up to
1 degree.
This relay provides protection from transmission system faults, where the mains voltage may be
absent or reduced for a significant period of time before the fault is cleared. Operation of the relay
and subsequent disconnection of the generator from the mains prevents possible loss of
synchronism ("pole slipping" or "out of step" operation) after the fault is cleared. When the fault
occurs the system impedance as seen at the generator terminals changes, with both real and
reactive components normally decreasing. The impedance change causes a rapid generator
loading change and voltage vector change, triggering the relay. In the unlikely circumstance of the
impedance change being gentle enough that the relay is not triggered when the fault occurs, then
should pole slipping occur when the fault is cleared, the violent load changes associated with pole
slipping are guaranteed to trigger the relay.
The vector disturbance relay is further energised upon the loss of a single or two phases. This is
achieved by utilising differential phase sensing.
56
Section 7
Form STC-010 rev A – Commissioning Procedures

--------------------------------------------------------------------------------------------------------------
Tests Conducted on Date ......................... By ...………........................
Generator Set ..................... Si-TEC Xtend module Ser No. ....................

--------------------------------------------------------------------------------------------------------------
NOTE: The procedures have been compiled with the assumption that they are
performed by personnel who are familiar with the commissioning of power
generation equipment.
Only suitably licensed personnel should conduct such works.
Read and understand the procedures fully BEFORE commencing.
Should any test not prove satisfactory, DO NOT PROCEED further.

STOP and check system design and/or installation.
Fully test all safety shutdown and emergency stop functions before
commencing.
7.1 Generator Setup
1 ISOLATE the generator circuit breaker from closure.

OK / .................
2 Check the actuator linkage travel. The actuator should be approximately 5% with the fuel
valve/rack fully closed and approximately 95% position with the fuel valve/rack fully open.
OK / .................
3 Check that the actuator linkage and valve/rack assembly operates freely through the full
travel range without binding, and that there is no "slop" from loose or worn joints.
OK / .................
4 Apply 24 volt DC supply to the Si-TEC Xtend module. The display should indicate power-up
tests, and then revert to the default SHUTDOWN display.
OK / .................
5 Scroll up twice to the "Actuator Info" display (menu 87). Manually move the actuator from
minimum to maximum. Check that the indicated feedback % agrees with the graduated scale
on the actuator side plate. If not, refer to the Fault Finding section.
OK / .................
6 The actuator test function will only operate with the engine in the “shutdown condition”. Scroll
to menu 081 “Set Actuator Position 1” in the “Actuator Test” sub menu. After entering the
menu press the “Bump” key to enable the actuator test. Changing the controlled value from 0
to 100% causes the actuator to drive from 0% to 100%. The feedback is on the display to the
left and expressed in %. At 0% actuator output the feedback should read about 5%. At 100%
actuator the feedback should read about 95%. The 5% and 95% feedback should be where
the actuator is driving hard against the zero fuel and full fuel mechanical stops respectively.
Set the controlled value to 50% and check that the actuator positions correctly at about 50%
with a feedback reading of around 50%. Check that the actuator attempts to restore the
position if the actuator arm is manually forced to 0% and to 100%. Use the 0% and 100%
actuator feedback calibration if the minimum and maximum readings are undesirable.
OK / .................
57
7 Check all the preset values and set them to the correct values for the application. Some
values (eg. PID settings) will not be known and should be left at the preset values until tuning
is done. Record all the set values in the space provided in the Menu Summary section. This
will provide a permanent written record of the control system settings.
OK / .................
The Si-TEC Xtend support software "Si-TEC pcConfigure" facilitates the cross loading of the
preset values to a PC (personal computer). Set values are easily stored, loaded, modified
and printed out. An on-line help system is included with the “Si-TEC pcConfigure” software.
8 Check fuel availability and bleed the fuel system if necessary. Confirm that the fuel filters are
in operating conditions. Conduct all preliminary pre-start procedures in accordance with the
prime mover manufacturer’s recommendations.
Static and functional tests of all safety shutdown systems should be checked prior to starting
the engine.
An independent shutdown system for over speed should be checked for correct operation
prior to proceeding with the commissioning.
OK / .................
9 Disconnect the main alternator excitation circuit to prevent voltage excitation of the generator
and subsequent voltage generation.
OK / .................
10 Set the Rated Speed input to “Low” (holds the set at Idle Speed). If the Rated Speed is not
selected as a logic input, the function should be set to “always OFF”. Ensure that the “Enable
Run” input (input 1) is active. Disconnect the actuator feedback terminal plug (terms 58 – 61).
This should cause a FEEDBACK HI ALARM on the display and will hold the actuator at
minimum fuel. Replace the feedback terminal plug and reset the alarm. Check the actuator
“Start Fuel Limit %” setting.
OK / .................
11 Activate the “Start Seq.” input (input 2) to initiate the cranking. If an external crank control is
used, initiate the cranking. Check the cranking cycle operation. The default display should
show the speed while cranking. The MPU fail safe facility will hold the actuator at 0% until
MPU pulses are received. Should a MPU frequency of less than 200Hz be required when
cranking, it will be necessary to set the “By-pass Fail Safe” to “YES”. This permits fuelling
without MPU signals during starting, although the MPU fail-safe will be switched to active
after receiving the first MPU signals.
Refer to the Fault Finding section.
OK / .................
12 Replace the feedback terminal plug and reset the alarm. The Rated Speed Input should
remain “Low” (holds the set at idle speed). Switch the “Start Seq” Input to “Low”, then back to
“High” to repeat the start procedure. The engine should start and control at the preset idle
speed. Adjust the idle speed PID settings for stable operation. Check that the LCD displays
the idle mode operation. (Refer to PID set up procedure)
OK / .................
13 Check the operation of all safety shutdown devices during the initial starting eg. over speed,
oil pressure, high temperature, emergency stop etc. (refer to the engine manufacturer’s
manual)
OK / .................
14 Switch the Rated Speed input to “High” or set the input to "always ON". The engine should
ramp to rated speed at the preset ramp rate. Adjust the Rated Speed PID settings to obtain
maximum response, along with stable operation. (refer to the PID set up procedure for full
tuning details) When the tuning is complete, set the “Approx Actuator Position at No Load”
(menu 363) value in the kWatt Control sub menu. The value to set can be read from the left
side of the display while the engine is operating at rated speed with no load.
OK / .................
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15 Shutdown and re-start the engine as necessary to optimise engine operation for the
requirements and site conditions with respect to:
Idle Speed
Idle Time
Speed Ramp Rates
Actuator Start Limit %
Start Limit Increment % / sec
Record all changed preset values in the Menu Summary section
OK / .................
16 Shutdown the engine. Check the phasing of the generator to the generator voltage inputs.
Red Phase: Input Aφ (terminal 104)
White Phase: Input Bφ (terminal 105)
Blue Phase: Input Cφ (terminal 106)
Neutral Point: Input N (terminal 107)
(Terminal 107 is not essential for 110Vac 3-phase, 3-wire PT inputs)
OK / .................
17 Ensure that the load bus is “dead” or the fuse is isolated. Check the phasing of the bus to the
bus voltage inputs.
Star Point: Input N (terminal 103)
(Terminal 103 is not essential for 110Vac 3-phase, 3-wire PT inputs)
OK / .................
18 Connect the excitation circuit of the main alternator to enable voltage generation. Check the
main power cabling for phase and earth isolation.
OK / .................
19 For MOP voltage Trimming: (to enable this function, set menu item 328 to “0”)
Set the voltage adjusting motorised operated pot (MOP) to its mid-point. For Dawson
Technology’s MOP, do not manually turn the clutch cylinder or cams. The MOP may be
controlled even while the engine is shutdown, by switching to manual mode control (“Auto”
input “Low”) and using the manual raise and lower Volts inputs. If the inputs are not wired to
terminals, the functions can be configured ON and OFF to control the motor pot.
Set the main voltage adjust on the AVR for MINIMUM Volts.
OK / .................
20 Start the generator.
For MOP voltage trimming: (to enable this function, set menu item 328 to “0”)
At no load set the main voltage adjustment for rated voltage. Raise the MOP to maximum
using the “Raise Volts” input (in manual mode). Check that the voltage is increasing. If
necessary, reverse the input connections to the MOP to ensure the correct output.
For Analog AVR biasing: (to enable this function, set menu item 328 to “1”)
The minimum and maximum DC voltage bias range should be set to suit the specific AVR
model (through menu items 334 and 335). If necessary, adjust the AVR Bias set points in the
“Voltage / AVR Control” sub menu for the correct voltage bias output range. The DC voltage
bias is displayed during this test. With the generator running and in the Si-TEC Xtend in
manual mode, (“Auto” input is “Low”) proceed to the “AVR Bias Output – Forced to” menu
item (menu 068) and use the “BUMP” key to force the bias test output. Check that the
maximum voltage reached is adequate (+15%) but not excessive. Lower the voltage and
check the low voltage range. Re-adjust the main AVR voltage control to optimise the
available voltage trimming range for the system conditions and kVAr loads. Please note that
kVAr generation on load will cause voltage droop and kVAr absorption will cause voltage
boost. The voltage P.I. must be tuned to stabilise the voltage control loop.
OK / .................
59
21 Check the phase rotation of the generator and change the main power connections if not
correct.
Should main power connections be altered, re-do tests 16 and 17 to confirm that the sensing
voltages have not been affected. Remember to change the generator current transformer
(CT) connections as well if the rotation has to be changed. Verify that the phases are correct
after the CT connection change.
OK / .................
22 Stop the generator. Reconnect the Generator Circuit Breaker (CB) for closure. Set the Si-
TEC Xtend module to manual mode (“Auto” input function switched “Low” or “always OFF”).
OK / .................
23 Set the MOP AVR trim pot for the operating (rated) voltage.
OK / .................
24 Ensure that the main bus is “dead”.

OK / .................
25 Start the generator and then externally close the CB on to a "No Load" dead bus.
NOTE THE NO LOAD BUS VOLTAGE
OK / .................
26 Apply an INDUCTIVE load by closing the Feeder circuit breakers to obtain a load of say 50 %
of the generator’s rated capacity.
The inductive load should be sufficient to obtain a power factor of between 0.70 and 0.90 and
best if this represents the actual connected load power factor.
OK / .................
NOTE: VOLTAGE DROOP MUST BE OPERATIVE FOR ALL GENERATORS WHETHER

PARALLELED TO OTHER GENERATORS (ISLANDED) OR TO THE SUPPLY GRID.
27 The voltage droop should be set to provide a droop representing around 3 - 4% of the rated
voltage at full load, and at what will be the maximum lagging power factor. The voltage droop
is affected by the actual power factor and the load. Verify the alternator manual or
specifications for setting of the voltage droop.
IMPORTANT NOTE:
The voltage droop should be set so that at FULL LOAD and at the LOWEST POWER
FACTOR achieved at full load operation, the droop DOES NOT EXCEED the 8% voltage trim
as outlined in item 20 above.
eg. At 50% load and a power factor of say 0.80 the droop should be set for:
5% of 240 Vac Ph/N = 12 Vac at full load at 50 % load = 12 x 50/100 = 6 Vac droop Ph/N.
For paralleled generators the voltage droop(s) should be set to provide similar droop levels
on all generators.
OK / .................
28 After the voltage droop has been set, the Si-TEC Xtend “Auto” input function should be set to
automatic mode. The generated voltage should now be trimmed to maintain the preset rated
voltage.
Vary the loads on the generator to check for correct adjustment of the generator output
voltage such that the preset operation voltage is obtained.
OK / .................
29 Check the correct direction of Current Transformer connections by monitoring the “Info /
Alternator” sub menu – the kWatts should display positive values for all three phases.
OK / .................
60
30 Note the response of the generator under changing loads and tune the rated PID preset
values to provide for the optimum governor control response, namely fast response to
transient load changes and stable steady-state response. The “Si-TEC PC Tune” software
package is available to assist with governor dynamics tuning.
OK / .................
31 Conduct Logic Input tests to confirm the correct application operation.

OK / .................
32 Conduct Relay Output tests to confirm the correct application operation.

OK / .................
33 Conduct Analog Input tests to confirm the correct application operation.

OK / .................
34 Conduct Analog Output tests to confirm the correct application operation.

OK / .................
35 SHUTDOWN the generator and conduct all of the above procedures for all the other Si-TEC
Xtend control modules to be used in the application.
OK / .................
7.2 Generator Synchronising and Parallelling
36 Check the menu preset values for both synchronising and parallelling of generators on ALL
the units.
Determine whether the “Si-TEC LAN” connections and terminators have been installed.
Verify the correct “Si-TEC LAN” communications by utilising the “Module to Module
Communications” sub menu. Scroll through the connected module numbers confirming that
the communication time (top right of the LCD screen) for each and every module displays ‘0’,
occasionally changing to ‘1’. This confirms the proper communications between all Si-TEC
Xtend modules in the system.
OK / .................
37 Select a "Lead" generator and close this lead set to the DEAD BUS.
OK / .................
38 ENSURE YOU ISOLATE the Circuit Breaker relating to the generator which is to be
synchronised to the Main Bus.
OK / .................
39 Start the generator as if it is to synchronise and parallel with the bus. WITH THE GEN CB
ISOLATED closure should not occur.
OK / .................
40 Check the synchronising control and the CB "CLOSE" signal. The CB close signal should
only operate when all three phases are within the preset phase window angle. Check this by
measuring the voltage across the generator circuit breaker. Steps 16 and 17 should have
already confirmed correct phase sensing at the Si-TEC Xtend module.
The CB close signal will not operate if the generator voltage is beyond the preset minimum /
maximum voltage levels.
The Si-TEC Xtend preset synchronising voltage window should be set to a value greater than
the Si-TEC Xtend preset voltage dead band.
OK / .................
61
41 Voltage on the same phase ACROSS THE CIRCUIT BREAKER (at the circuit breaker)
should be less than 5% of the line to line Volts when a “Close CB” relay output is energised
(terminals 17 & 18). along with the corresponding LED indication.
Check and note voltage difference on RED (A) PHASE
Check and note voltage difference on WHITE (B) PHASE
Check and note voltage difference on BLUE (C) PHASE
OK / .................
42 DO NOT CONTINUE IF STEP 41 SHOWS THAT THE PHASES ARE NOT IN

SYNCHRONISM WHEN THE CB CLOSE SIGNAL IS ACTIVATED.
OK / .................
43 Adjust the Synchronising Proportional (gain) if necessary, to achieve the optimum

synchronising control response.
Note: The Synchronising Proportional will bias the Rated PID settings during synchronising.
OK / .................
44 STOP the generator and remove the inhibit of the CB closure.

OK / .................
45 Re-starting the generator will now permit CB closure upon the generator synchronising with
the main bus. Check that the Gen CB (input 3) is energised when the generator CB closes.
OK / .................
46 Monitor the synchronising, kWatt ramping, load sharing, and kVAr sharing of the sets.
Trimming of the load is not necessary if the preset kWatt rating and CT ratios have been set
correctly. Adjustments may be made to the kWatt ramp rate and Volts adjust rate to suit the
application.
OK / .................
47 Conduct tuning of the kWatt P.I and the kVAr P.I. to provide responsive and stable load and
VAr sharing dynamics.
Set preset dead band of kWatt and kVAr to obtain fine and stable control.
OK / .................
48 After ensuring that the other sets on the load bus have the capacity to carry the load, de-
energise input 2 (Start Seq.) to permit the unloading, opening of the Gen CB, and engine
cool down cycle to commence. The generator should shutdown after the preset cooldown
time has expired.
OK / .................
49 Conduct operation 37 to 48 for each of the paralleled generators.

OK / .................
7.3 GSM Master Module
50 Set all menu preset values. Configure the module for the desired control functions. Refer to
the GSM menu items.
OK / .................
51 Check the phasing of the Load Bus to the Load Bus potential inputs.
(Terminal 107 not required for 110Vac 3-phase, 3-wire PT inputs)
OK / .................
62
52 Check the phasing of the Line Bus to the Line Bus potential inputs.
(Terminal 103 not required for 110Vac 3-phase, 3-wire PT inputs)
OK / .................
53 Conduct Logic Input tests to confirm the correct application operation.

OK / .................
54 Conduct Relay Output tests to confirm the correct application operation.

OK / .................
55 Conduct Analog Input tests to confirm the correct application operation.

OK / .................
56 Conduct Analog Output tests to confirm the correct application operation.

OK / .................
57 ENSURE THE ISOLATION of the Circuit Breaker relating to the switched output of the GSM
module.
OK / .................
58 Start the generator as if it is to synchronise and parallel to the bus. WITH THE CB
ISOLATED closure should not occur.
OK / .................
59 Check the synchronising control and the CB "CLOSE" signal. The CB close signal should
only operate when all three phases are within the preset phase window angle. Check this by
measuring the voltage across the switched circuit breaker. Steps 51 and 52 above should
have already confirmed correct phase sensing at the Si-TEC Xtend module.
The CB close signal will not operate if the bus voltage is beyond the preset minimum /
maximum voltage levels.
OK / .................
60 Voltage on the same phase ACROSS THE CIRCUIT BREAKER (at the circuit breaker)
should be less than say 5% of the line to line Volts when a circuit breaker close signal is
output on terminals 17 & 18.
Check and note voltage difference on RED (A) PHASE
Check and note voltage difference on WHITE (B) PHASE
Check and note voltage difference on BLUE (C) PHASE
OK / .................
61 DO NOT CONTINUE SHOULD STEP 59 PROVE THAT THE PHASES ARE NOT IN
SYNCHRONISM WHEN THE CB CLOSE SIGNAL ACTIVATED.
OK / .................
62 Adjust the Synchronising Proportional (gain) in the menu presets to achieve the optimum
synchronising control response.
OK / .................
63 Remove the inhibit of the CB closure enabling closure of the circuit breaker.
OK / .................
64 The main bus will now be permitted to synchronise to the incoming supply and provide CB
closure.
OK / .................
63
65 Check the correct direction of Current Transformer connections by monitoring the “Info /
Alternator” sub menu for kWatt and kVAr readings, ensuring that values for all three phases
are positive for export and negative for import.
OK / .................
66 Monitor the synchronising, kWatt ramping, and Power Factor control of the mains supply.
Adjustment of the Import / Export kWatts and kVAr can now be conducted by adjusting the
relative reference set point.
OK / .................
67 Check the Analog outputs to verify correct calibration.

OK / .................
68 REPEAT items 50 to 67 for additional GSM modules.

OK / .................
64
8 FAULT FINDING
Engine-Generator control system check list
(a) Check for correct logic input signals for the required mode of operation.
(b) Check for loose terminations, wiring faults, and faulty contacts.
(c) Check the fuel system for adequate supply (and filters) and/or air ingress.
(d) Check the actuator linkages for any binding or excessive slop (lost motion).
(e) Check the Circuit Breaker (CB) auxiliary contact input for correct operation.
(f) Check if Voltage Droop CTs are connected, and if reversed or on the incorrect phase.
(g) Check if the Voltage Droop of all generators is correctly set.
(h) Check the AVR settings, for proper control stability and operation.
Note: After the generator has been commissioned the PID settings should not require any
adjustment. Unless changes to fuel, linkages, engines, etc. have been made no error would be
expected due to the PID settings. If the cause for any of the following fault conditions are stated as
“Incorrect PID Settings”, this would mean that the commissioned PID settings may have been
adjusted and should be re-tuned back to the original commissioned values.
Most Common Faults and their Causes
1) Instability of Engine Governor with Generator CB Open

a) Check fuel system and mechanicals (including filters, linkages etc.).
b) Check for free movement in linkages of the actuator and fuel system.
c) Check for excessive "SLOP" (lost motion) in linkage system.
d) The actuator feedback may have faulted.
e) The MPU cabling or Actuator feedback may have faulted.
f) The screen (shield) of the MPU or actuator feedback cables may have faulted.
g) Incorrectly tuned P.I.D settings.
2) Sluggish operation of Engine Governor with Generator CB Open

c) Incorrectly tuned P.I.D settings.
3) Actuator torque output relaxes momentary after a time period (15 sec +)
a) Actuator is operating in current limit.
b) Linkages and/or actuator are not moving freely due to binding.
c) Torque requirement too great (larger actuator required).
4) Generator does not take load (kWatts) after CB Closes.

If the actuator is near full position and still at low load then most likely a fuel or
mechanical problem exists.
b) Check Gen. CB auxiliary input (input 3) status.
This must be closed (“High”) to enable load (kWatt) control operation.
The default display would most likely still display the "Synchronising Mode".
c)* Check Mains CB auxiliary input (input 4 – for CGC only).
This must be closed for grid parallelled kWatt control.
d) Check for free movement in linkages of the actuator and fuel system.
e) The actuator feedback may have faulted.
65
5) CB tripped on over current or Excess kWatt Load
a) Check phase Currents and Voltages in the “Info / Alternator” sub menu. This may
be because of a reversal in voltage or current sensing, or an open circuit.
c) The actuator feedback may have faulted.
6) CB tripped on reverse power

c) The actuator feedback may have faulted.
7) Incorrect kWatt, kVAr, current

b) Check the phasing of the voltage and current inputs. If the phase rotation for
synchronising has been confirmed as correct, do not change the voltage inputs or
the current sensing inputs.
c) Incorrect kVAr (lead/lag reversed). Rotate both the bus voltage and generator
voltage inputs and the current inputs. (ie. change the rotation sensing of the
module)
8) Generator stops for no apparent reason

b) Check the actuator operation (conduct actuator test).
c) Check the MPU input signal.
d) Check the 24Vdc supply (10 Amps rated for 20 seconds, & 6 Amps continuous).
(Minimum of 20Vdc on cranking - min 20Vdc / max 32Vdc running)
9) Instability of kWatts when parallelled to the supply grid

a)* Check if the Mains CB input (input 4 – CGC) is active, advising the module to
operate in “Paralleled to Grid” PID dynamics, and/or “kWatt” and “kVAr/PF” control.
b)* Incorrect tuned parallelled P.I.D. settings for:
* Governor “Paralleled to Grid” PID.
kWatt and/or kVAr Proportional / Integral settings.
c) Fuel supply or mechanical problem.
10) Instability of kVArs in Island operation or parallelled to the supply grid

a)* Check if the Mains CB input (input 4 – CGC) is active, advising the module to
operate in “Paralleled to Grid” PID dynamics, and/or “kVAr/PF” control.
b) Incorrect tuned parallelled P.I.D. settings.
Voltage Dead Band
Pulse Length
kVAr Proportional / Integral settings
c) AVR stability problem – tuning of the AVR may be required.
d) Voltage droop CTs of alternator are not connected, or they function incorrectly.
(Voltage droop must be set for parallelled generators, including paralleling to the
supply grid)
e)* Instability with the Supply Grid Voltage.
11) Generator not synchronising

a) “Auto” Input is de-energised (logic input switched “Low”, or set to “always OFF”).
b) “Sequence Hold” input is energised (logic input switched “High”, or “always ON”).
c) The phase rotation not correct.
d) The Synchronising Proportional (gain) preset value requires adjustment.
e) Low or High voltage input(s) to Bus or Generator voltage inputs.
f) Voltage is not within the "voltage window", and voltage correction is not functioning.
g) The "Synchronising Bias" setting is incorrect.
66
12) Engine not operating at Rated RPM (with generator CB open)
a) “Rated Speed” Input is not energised or is set to “always OFF”.
b) Si-TEC Xtend control is in manual mode. Check the “Auto” input logic status.
c) Check the fuel system, binding in linkage, etc. (also check Menu 108)
d) Incorrect "No Of Teeth" , "Rated RPM" or "Gear Reduction Ratio"
13) No MPU signal at module input terminals

a) Check the MPU wiring.
b) Check the air gap (should be no more than 2/3 turn from the flywheel gear tip).
c) Other connected device wiring may conflict with the Si-TEC Xtend MPU input. With
the engine stationary (shutdown) and the MPU disconnected, check that terminal
79 (MPU1) and terminal 84 (MPU2) of the Si-TEC Xtend module has resistance
reading above 1000 ohm. Note that terminal 80 (MPU1) and terminal 85 (MPU2) of
the Si-TEC Xtend module is referenced to ground.
d) MPU sensing end damaged or fouled.
14) Si-TEC Xtend module - DIAGNOSTIC MENU - Trip Cause

The "Trip Cause" displays the reason and elapsed time since the last opening of the
Generator Circuit Breaker. The five (5) most recent causes for the trip are displayed
through the description as follows:
1 : Reverse kW Alarm
2 : High kW Alarm
3 : Reverse kVAr Alarm
4 : High kVAr Alarm
5 : Phase Unbalanced Alarm
6 : Under Frequency Alarm
7 : Over Frequency Alarm
8 : Under Voltage Alarm
9 : Over Voltage Alarm
10 : Normal Off from PARA
11 : CB on in wrong State
12 : Microprocessor Reset
13 : External Trip
14 : Run Input Removed
15 : Loss of MPU signal
16 : Actuator Feedback Low
17 : Actuator Feedback High
18 : Normal Off Single
19 : Normal Off from ISOL
20 : PARA Off timeout
21 : Start Failure
22 : Speed Deviation
23 : Vector 3 phase loss
24 : Vector ph. unbalanced
25 : ONLINE Off in MAN.
The corresponding “Modbus” addresses for the trip causes are as follows:
Modbus address Reason for CB trip

5832 Most recent trip
5833 Previous to 5832
67
9 Si-TEC Xtend Communication Addresses accessed from RS232
Communications Port and User RS485 Port
The RS232 port utilises "MODBUS" ASCII protocol for the TGC and CGC Modules, and both RTU
and ASCII protocols for the GSM Modules.
The optional “User RS485” port supports both “MODBUS” ASCII and RTU protocols, and supports
both read and write functions for extensive addressing of the Si-TEC Xtend module. The
addressing supported includes for those detailed below, menu preset values, and selected
diagnostic data points.
The “Si-TEC pcConfigure” and the “Si-TEC pcTune” software utilise the RS232 port of the Si-TEC
Xtend control module.
It is noted that the master module data address points differ in part from the address points of the
TGC and CGC modules. The following addresses may be read from the TGC, CGC or GSM
modules for generator data addresses. Please refer to the GSM manual for details of the master
data address points.
Should the application require to “Write” to the Si-TEC Xtend module (eg. PLC or Supervisory
system), it is necessary to initially write to Modbus address 5503 with a value of 200. Subsequently,
specific values for the Modbus addresses may be written to carry out the appropriate functions.
For example:
Function Address Value
Reset 5501 200
Store 5509 47951
9.1 Si-TEC Xtend module Address Range
Module/Gen Start Address Module/Gen Start Address
0 46000 12 47200
1 46100 13 47300
2 46200 14 47400
3 46300 15 47500
4 46400 16 47600
5 46500 17 47700
6 46600 18 47800
7 46700 19 47900
8 46800 20 48000
9 46900 21 48100
10 47000 22 48200
11 47100 23 48300
Module 23 may be selected as a generator module or a master module, where module 0 can only be
assigned as a master module.
The RS232 cable pin connections are: 2 to 2 : 3 to 3 : and 5 to 5.

The ground pin 5 is at the 24Vdc supply battery negative voltage.
68
9.2 Generator Module Address (offset) Data Reference
Address Data Item Bytes

Offset
0 Voltage Error 1
1 Generator State 1 (refer to table 1)
2 Generator kWatt 2
3 Generator kVAr 2
4 Generator Rated kW 2
5 Generator RPM 2
6 Desired Actuator Percent (Hi byte) 2
7 Feedback Actuator Percent 1
8 Programmable Data Point 2
9 Analog Input 3 1
10 Communications Timeout (0-31) 1
11 Average Current 2
12 Average Generator Voltage (ph/neut) 2
13 Average Bus Phase/N Volts 2
14 Logic Status 1,2 1 (refer to status & alarms table)
15 Alarm Functions 1 (refer to status & alarms table)
16 Alarm Functions 1 (refer to status & alarms table)
17 Average Actuator Current 1
18 Analog Input 4 1 (RTD)
19 Analog Input 2 1 (O.P.)
20 Logic Input 1 1 (refer to logic input 1 & 2 table)
21 Logic Input 2 2 (refer to logic input 1 & 2 table)
22 Generator kWatt A phase 2
23 Generator kWatt B phase 2
24 Generator kWatt C phase 2
25 Generator Current A phase 2
26 Generator Current B phase 2
27 Generator Current C phase 2
28 Generator Volts A phase 2
29 Generator Volts B phase 2
30 Generator Volts C phase 2
31 Minimum Control kWatt 2
32 Frequency 2
33 Power Factor 1
Notes:
1) kWatt and kVAr (items 2 & 3) are transmitted as 2's complement of 65536
2) Frequency (item 32) is in two decimal places (ie. 50Hz transmitted as 5000)
3) Power Factor (item 33) is two decimal places and value is 2's complement of 256 (this is to
provide possible negative values)
4) The Modbus protocol provides for all data to be transmitted as word values.
It is noted that the master module (GSM) data address points differ from the address points of the
TGC and CGC modules. The above addresses may be read from TGC, CGC or GSM modules for
generator data. Please refer to the GSM manual for details of the master data address points.
69
9.3 Generator State Table 1 (address offset 1)
Bottom 5 bits Reciprocating

Value
0 Alarm Shutdown
1 Engine Shutting Down
2 Engine is Shut Down
3 Start Fail
4 Pre-Heat / Crank State 1
5 Crank Wait
6 Crank Attempts
7 Start Check
8 External Crank
9 Idle
10 Ramping to Rated Speed
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 Warm up at Rated Speed
16 Synchronising .
17 Reserved
18 Generator On-Line (isolated) with load ramping up
19 Generator On-Line and load sharing
20 Generator On-Line (isolated) with load ramping down
21 Generator On-Line (parallelled to grid) with load ramping up
22 Generator Parallelled to Grid
23 Generator On-Line (parallelled to grid) with load ramping down
24 Cooldown Mode
25 Not Used
26 Not Used
27 Not Used
28 Not Used
29 Not Used
30 Not Used
31 Not Used
Upper 3 Bits of address offset 1

+32 Sequence hold or kWatt Limited
+64 Under Manual Control
+128 Never Used (reserved for use by master module)
Note: A Generator can only be in one of the 0-31 states at any one time. Addition of the value of the
upper 3 bites provides the additional state.
It must be noted that the master module (GSM) address points differ in part from the address points
of the TGC and CGC modules. The above addresses may be read from the TGC, CGC or GSM
70
9.4 Generator Status and Alarm Tables (logic items)
Address Address Address

offset 14 offset 15 offset 16
Bit Bit Value Status 1,2 Alarms Alarms
15 32768 Reserved Reserved Reserved

14 16384 Reserved Reserved Reserved
13 8192 Reserved Phase Angle Shift Reserved
12 4096 Reserved Vector 3 Phase Loss Reserved
11 2048 Reserved Phase Unbalance Reserved
10 1024 Reserved Vector Ph. Unbalanced Reserved
9 512 Reserved Export kW High MPU2 Failure
8 256 Reserved Import kW High MPU1 Failure
7 128 kWatt Level Sw Over Voltage Variable Error
6 64 Import Limit Under Voltage Speed Deviation
5 32 Synchronising Over Frequency Start Fail
4 16 Trip CB active Under Frequency Sync Failure
3 8 Speed switch 1 High kVAr MPU Failure
2 4 Not Used Reverse kVAr DC Supply Low Volts
1 2 Fuel Solenoid High kWatts High Actuator FB
0 1 NOT Used Reverse Power Low Actuator FB
9.5 Generator Logic Input 1 & 2 Tables
Address Address
offset 20 offset 21
Bit Bit Value Logic 1 Logic 2
15 32768 Reserved Lower Speed

14 16384 Reserved Lower Volts
13 8192 Reserved Rated Speed
12 4096 Reserved Reserved
11 2048 Reserved Dead Bus Close
10 1024 Reserved Raise Speed
9 512 Reserved Raise Volts
8 256 Reserved Generator Available (input 1)
7 128 Reserved Gen CB Closed (input 3)
6 64 Reserved Mains CB Closed
5 32 kWatt Derate Auto
4 16 O/Speed Test Sequence On Line (input 2)
3 8 Load Share Enable Reserved
2 4 Fast Rate Reserved
1 2 Sequence Hold Reserved
0 1 Mains Bus Reserved
It must be noted that the master module (GSM) data address points differ from the address points
of the TGC and CGC modules. The above addresses may be read from the TGC, CGC or GSM
71
Appendix
Si-TEC Xtend
Control
Illustrations
72
Si-TEC Xtend Navigation Chart - Main Menu Level
Module Identification - 'Info. Only'
Sys. Diagnostics & Functional Tests
"Home Screen" (Default Display)
Instrument Data - 'Info Only'
Configure Module - For Your Appl.
Speed Governor - Control
Generator / Alternator - Control
Manual Mode - Setpoint Parameters
Logic and Analog I/O - 'Configure'
Relay Outputs/Alarms - Switch Pts.
Note:
Only the ∇ or the ∆ scroll keys are
used to navigate at the Main Menu
level.
Si-TEC Xtend Navigation Chart - Sub Menu Level
(Example : "Speed Governor Control" sub menus)
Speed Governor - Control

Main Menu
Select
Menu
Speed Control Set Point Parameters
Start Sequence - Actuator
Sub
PID Adj. - Speed Loop Response
Menus
Performance Enhanced - PID Adj.
Multi Point PIDs for Island Mode
Next Main Menu
Generator / Alternator Control
Note:
(1) Pressing the "Select Menu" key will navigate
to the first sub menu header under that main
menu.
(2) Pressing the ∆ key at the first sub menu
header will scroll back to the main menu level.
(3) Pressing the ∆ or ∇ keys allows navigation
along the sub menu level.
(4) Pressing the ∇ key at the last sub menu
header will scroll to the next main menu level.
Si-TEC Xtend Navigation Chart - within Sub Menu
(Example : "Multi Point PIDs for Island Mode")
Multi Point PIDs for Island Mode
Select
Menu
Enable Multi Point speed PIDs (Y/N)
Proportional at 100% kWatt Load
Integral at 100% kWatt Load
Derivative at 100% kWatt Load
% of Rated kWatts for Mid-Pt. PIDs
Proportional Mid Point kWatt Load
Integral Mid Point kWatt Load
Derivative Mid Point kWatt Load
[ End of Sub Menu ]
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Si-Tec Setup and Commissioning Manual

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Si-Tec Setup and Commissioning Manual

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Si-TEC Xtend series

TGC (Total Generation Control) + CGC (Co-Generation Control)

Set Up and Commissioning Manual

Manual No. 549-011 rev A

Dawson Technology Pty Limited

1 Configuring the Module 1

2 Si-TEC Xtend Menu Preset Item Description for Reciprocating Engine

3 Detailed Description of the Menu Items 15

6 Operation and Service Information 51

7 Form STC – 010 rev A 57

9 Si-TEC Xtend Communication Addresses accessed from RS232

The following is a description of terms used within this document:

Analog Input: RTD, 0-5V, or 4-20mA input signals.

Analog Output: 4-20mA output for driving external metering etc.

Logic Input: a switched input voltage (nominally 24Vdc).

Relay Output: voltage free contacts for providing output control.

High Input: when 24Vdc is applied to a logic input.

Low Input: when the logic input has 0Vdc applied.

Generator CB: the respective generator circuit breaker.

1.3 Navigating the Menu System and Tips

Trip Cause – Information (Sub Menu)

Module to Module – Communications (Sub Menu)

Display I/O States (Sub Menu)

Force Outputs Test (Sub Menu)

Actuator Test (Sub Menu)

Instrument Data – Control Parameters

Info / Synchronising (Sub Menu)

Info / Alternator (Sub Menu)

Info / Actuator (Sub Menu)

Info / Peak Hold (Sub Menu)

Configure ‘Module’ For Your Application – Main

VT and CT Ratio (Sub Menu)

Module Setup (Sub Menu)

Start Sequence – Actuator (Sub Menu)

PID Adj. - Speed Loop Response (Sub Menu)

Performance Enhanced- PID Adj. (Sub Menu)

Multi Point PIDs - Island Mode ‘On Load’ (Sub Menu)

Generator / Alternator – Control Function Set

Frequency (Hz) - Set Point Parameters (Sub Menu)

Synchronising - Set Point Parameters (Sub Menu)

Voltage / AVR Control – Set Point Parameters (Sub

kWatt Control - Set Point Parameters (Sub Menu)

kVAr / PF Control – Set Point Parameters (Sub Menu)

Manual Mode - Set Point Parameters

Logic and Analog I/O – ‘Configure’ ‘Set

Logic Inputs - Allocate a Task to an Input (Sub Menu)

Logic Outputs - Allocate a Function to a Relay (Sub

kWh / kVArh Meter - Pulsed Output (Sub Menu)

Analog Inputs - Allocate to Input (Sub Menu)

Analog Outputs - Assign Data Type (Sub Menu)

Relay Outputs / Alarms – Switch Set Points -

Speed (RPM) – Switch Set Points (Sub Menu)

Volts / Frequency – Switch Set Points (Sub Menu)

kWatt – Switch Set Points (Sub Menu)

kVAr – Switch Set Points (Sub Menu)

Group Switch Points - 'together' to Form Combined

Miscellaneous – Switch Point Limits (Sub Menu)

Paralleled to Mains Switch Point (Sub Menu)

Vector Disturbance – Switch Point Limits (Sub Menu)

3.1 Module Identification – Information Only – Main Menu

3.2 System Diagnostics and Functional Tests – Main Menu

3.3 Instrument Data – Control Parameters ‘Information Only’ – Main Menu

Info / Synchronising – Sub Menu

Info / Alternator – Sub Menu