DEIF DELOMATIC 400 Gas Engine Unit Control System

DEIF DELOMATIC 400 Gas Engine Unit Control System

In the field of modern distributed energy and cogeneration, the requirements for generator control systems are far beyond basic start stop and protection. Faced with increasingly complex gas engine technology, strict emission regulations, and the demand for unmanned operation and maintenance, a comprehensive solution that integrates advanced control algorithms, precise measurement protection, and remote communication capabilities has become an inevitable choice. The DELOMATIC 400 launched by DEIF is designed specifically for this purpose, as a modular process controller for power plants driven by gas engines. This article will delve into the architecture, core functions, technical specifications, and unique application value of the system in the field of gas energy based on its official technical data manual.

Chapter 1 System Application and Hardware Overview

1.1 Core positioning and application scenarios

DELOMATIC 400 is not a universal PLC, but a process controller deeply customized for gas/hydro power plants. Its design philosophy revolves closely around four core keywords: reliability, robustness, flexibility, and remote accessibility. The system has been optimized specifically for the challenges of harsh environments and remote areas, such as offshore platforms and land-based distributed power stations, and has strong environmental adaptability.

The foundation of this controller is derived from DEIF's mature generator control system, which has been applied to thousands of ships and land-based power plants for over 25 years. This background endows DELOMATIC 400 with inherent high industrial standards and anti-interference capabilities. The system is designed specifically for unmanned operation, and its human-machine interface not only provides comprehensive information for local users, but also supports efficient remote diagnosis and rapid recovery operations.

In terms of system integration, DELOMATIC 400 demonstrates extremely high openness and can seamlessly communicate with external specialized devices, such as:

ignition system

Detonation suppression system

Gas Mixing Control System

Other third-party fieldbus devices

This enables it to serve as a central control unit, coordinating the efficient and safe operation of the entire engine generator set.

1.2 Standard Function Collection

The DELOMATIC 400 integrates numerous complex functions into one, greatly reducing the complexity and cost of system integration. Its standard functions cover the complete chain from measurement, protection to advanced strategy control:

Comprehensive measurement capability:

Electrical parameters: three-phase generator/grid voltage, three-phase current, single-phase/total active/reactive power, active/reactive energy count.

Mechanical and process parameters: operating hours, number of circuit breaker operations, all critical engine temperatures and pressures, and other measured values of the power plant.

Core protection and control functions:

Grid connection and generator protection: including comprehensive electrical protection such as vector tripping, frequency change rate, over/under voltage, over/under frequency, current asymmetry, reverse power, low power, overcurrent, thermal overload, over/under excitation, overspeed, etc. Integrated grid protection function to meet grid access standards.

Security and Logic Control: Supports hardware security chain and reset function; Perform disconnect proof monitoring on the position of the circuit breaker; Configure emergency shutdown; Provide configurable universal fault inputs; Manage the pre/post operation of auxiliary equipment; Control the opening and closing of electric circuit breakers.

Power and synchronization control: built-in analog power setpoint; Capable of voltage regulation and power factor control; Integrated automatic synchronizer with voltage matching and timeout monitoring; Built in electronic governor with acceleration control function, eliminating the need for an external governor unit; Smooth start stop power ramp function.

1.3 Special functions for gas engines

Different from diesel generator sets, DELOMATIC 400 integrates a large number of dedicated control and monitoring logic for gas engine characteristics:

Engine status monitoring:

Lubricating oil pressure/temperature monitoring

Coolant temperature monitoring

Gas pipeline pressure/temperature monitoring

Gas leak detection

Gas valve opening time monitoring (to ensure safe ignition)

Monitoring of exhaust temperature after turbocharger

Exhaust back pressure monitoring

Water level limiter for coolant, emergency cooler, and heating circuit

Monitoring the execution time of the air door baffle

Exhaust bypass valve execution time monitoring

Starter gear to gear monitoring (to prevent damage to the starter gear)

External oil level monitoring (low fresh oil level, high waste oil level)

Advanced Process Control Strategy:

Fully automatic engine start stop sequence

Warm up control

Engine Rear Run Cooling Control

Automatic load shedding function based on multiple parameters: adjust output according to intercooler temperature, throttle position, ambient temperature, exhaust temperature, etc., to prevent the engine from entering dangerous operating conditions.

Peak regulation: Optimizing power generation output based on grid demand or economic efficiency.

Thermal Follow Control: Adjust the power output of power generation based on thermal demand (such as heating network demand) to maximize the benefits of cogeneration.

Methane value control: Engine operating parameters can be adjusted based on changes in gas quality (methane value).

Gas level/pressure control: Adjust the power generation based on the gas supply situation.

Closed loop control: controls the engine cooling circuit, emergency cooling circuit, and heating circuit; Control the gas mixing ratio; Control the exhaust bypass valve; Control the ventilation damper in the computer room; Control the intake air damper.

Chapter 2 Hardware Architecture and Technical Specifications

The DELOMATIC 400 system adopts a highly integrated modular design, consisting of only three core hardware modules, greatly simplifying spare parts inventory and maintenance complexity. All modules are installed in standard industrial chassis for high-speed and reliable data exchange through backplane bus.

2.1 PCM 4.3 Power and Control Module

PCM 4.3 is the brain and heart of the system, located on the far left side of the chassis (8TE width). It is responsible for supplying power to all modules inside the chassis and managing data exchange on the backplane. The module is equipped with a high-performance processor, running core application software and providing rich communication interfaces.

Power supply: 18... 36 Vdc, maximum 6A.

Core functions: Provide power to all modules, manage backplane data bus, and run application programs.

Processor and Operating System: The 180 MHz processor and Linux 2.6 operating system ensure real-time performance and stability of the system.

Storage: 64 MB SDRAM, 32 Kb non-volatile RAM, 16 MB FLASH (for program and data storage).

Communication interface:

3 x CAN bus: used to connect local devices such as engines and generators.

1 x RS422/485: Supports serial communication protocols such as Modbus.

1 x ARCNET: Used for high-speed connection of expansion chassis to achieve system expansion.

1 x Ethernet port (10/100 Mbit): This is the external portal of the system, supporting TCP/IP protocol, which can realize local touch screen connection, upper computer monitoring, and remote access.

1 x USB service interface (exclusively for use by DEIF personnel for debugging).

I/O: 1 digital relay output (normally open, 8A), 1 digital input (5V/7.5mA).

2.2 PCM 4.4 Distributed I/O and Fieldbus Controller

When the slots in one chassis are insufficient to accommodate all I/O modules, PCM 4.4 is used as the controller for the expansion chassis. The PCM 4.3 of the main control chassis communicates with PCM 4.4 through the high-speed ARCNET bus to achieve smooth system expansion. Its technical specifications are similar to PCM 4.3, but focus on I/O expansion and fieldbus management.

Power supply: 18... 36 Vdc, maximum 6A.

Core function: Expand the controller of the chassis and manage distributed I/O.

Interface: 3 x CAN, 1 x RS422/485, 1 x ARCNET, 1 x display port.

Storage: 2 MB RAM, 32 Kb non-volatile RAM, 1 MB FLASH.

2.3 IOM 4.2 Multifunctional I/O Module

IOM 4.2 is the "sensory and sibling" of the system, a highly flexible 40 channel multifunctional I/O module designed specifically for harsh environments. All inputs and outputs are isolated from other potentials through photoelectric isolation, ensuring the anti-interference ability and safety of the system.

Digital input (12 channels): 9... 36 Vdc or -9... -36 Vdc, impedance of approximately 2.4 k Ω, optoelectronic isolation 550 Vdc.

Frequency/digital input (4 channels): 9... 36 Vdc, impedance 2.4 k Ω, can measure frequency signals up to 20 kHz, resolution 0.8 microseconds, very suitable for high-speed signal access such as speed sensors and flow meters.

Digital output (10 channels): External power supply 9... 36 Vdc, each channel can provide up to 200 mA of source current or sink current. Equipped with short-circuit and overload protection, and sends an alarm to the main controller in case of a fault.

Temperature input (6 channels): Supports Pt100, Pt1000, and NiCr Ni thermocouples, with a temperature measurement range of -50 to 1000 ° C. Supports 2/3/4 wire connections for PT sensors and can detect open and short circuit faults. The accuracy under 4-wire connection can reach up to 0.5 ° K.

Analog input (4 channels): configurable to -20... 20 mA or -10... 10 V, 16 bit resolution, accuracy 0.5%.

Analog output (4 channels): -20... 20 mA signal, load 0... 500 Ω, 12 bit resolution, accuracy 0.5%.

Isolation: Analog input, analog output, and temperature input share the same potential, but are optically isolated from all other potentials by 550 Vac.

2.4 SCM 4.1 Measurement and Protection Module

SCM 4.1 is the "eye" of the system, a 0.5 level accuracy AC measurement and protection module. All measured values (voltage, current, frequency, power, phase angle, etc.) are transmitted in real-time to the main controller at each cycle for control logic. The integrated protection function within the module can directly control the output of two dedicated relays, ensuring the fastest and most reliable tripping of the generator in case of electrical faults.

Input:

Two sets of three-phase voltage inputs (L1, L2, L3, N): can directly measure voltages up to 690 Vrms (40... 70 Hz). The range can be expanded through voltage transformers. Continuous overload capacity of 130% Un.

One set of three-phase current inputs (L1, L2, L3): accepts standard 1A or 5A CT secondary side signals. Continuous overload capacity of 20 A.

Measurement level and function:

0.5 level accuracy (compliant with IEC 60688 standard), capable of accurately measuring voltage, frequency, current, power, reactive power, and phase angle.

Configurable power grid protection functions, such as vector jump detection.

Harmonic measurement capability up to 500 Hz.

output:

2-channel relay output:

1-way normally open (NO): used for synchronization check and closing permission.

1-channel normally closed (NC): driven directly by the protection function, serving as a trip outlet to ensure safe tripping in extreme situations such as controller failure.

Isolation:

There is an isolation voltage of 3.25 kV between voltage measurement inputs and other potentials.

Isolation between relay output and other potentials: 2.2 kV.

Isolation between digital input (for feedback monitoring) and other potentials: 550 V.

2.5 Installing the chassis

The system provides three standard sizes of chassis to accommodate application needs of different scales:

24 TE (TE is the modulus unit, 1TE=5.08mm): can install 2 modules+power/processor modules.

42 TE: Can install up to 4 modules+power/processor modules.

60 TE: Can install up to 8 modules+power/processor modules.

This flexible chassis design allows users to build controller systems ranging from compact to large based on actual I/O points.

Chapter 3 Human Computer Interaction and Remote Monitoring

The user interface design of DELOMATIC 400 fully considers the dual requirements of local operation and remote management.

3.1 Local Visualization and Operation

The system supports local interaction through the following methods:

Touch panel PC (optional): Provides an intuitive graphical user interface.

Standard PC/laptop: can be directly connected to the controller via USB or TCP/IP.

The interface has powerful functions, including:

Full graphical display: All measured values can be displayed in real-time in both graphical and numerical forms. A vivid P&I process flowchart can dynamically display changes in equipment status and process values.

Trend recording: Built in trend function, capable of curve recording and analysis of key parameters.

Event and alarm logs: Contains over 200 time stamped records for easy fault tracing.

Parameter adjustment: Authorized users can directly adjust controller parameters on the interface.

Multi user support: Supports multi-level user permission management.

3.2 Remote Access and Maintenance

Thanks to the built-in Ethernet interface and TCP/IP support, remote access has become a standard feature of DELOMATIC 400. Users can monitor, diagnose and even adjust parameters of power stations anywhere in the world through standard Internet connection. This capability is crucial for maintaining unmanned power stations located in remote areas or offshore platforms, greatly reducing fault response time and lowering operational costs.

In addition, the system also integrates maintenance reminder function based on running hours, which can automatically generate and push maintenance notifications according to the actual operation of the device, achieving predictive maintenance.

Chapter 4 Emission Control and Advanced Application Strategies

Faced with increasingly stringent environmental regulations, the DELOMATIC 400 integrates advanced emission control functions, making it stand out among similar products. The system can select different control strategies based on user configuration to optimize the combustion process and reduce harmful emissions such as NOx

Based on oxygen sensor control: By closed-loop control of air-fuel ratio, the engine operates in the optimal combustion range.

Based on intake manifold pressure/temperature control: By monitoring the state of the mixture entering the cylinder, the fuel injection quantity is precisely controlled.

Based on combustion chamber temperature control: directly or indirectly monitoring the combustion temperature, controlling the combustion temperature within the optimal window by adjusting the air-fuel ratio, thereby effectively suppressing the generation of NOx.

In addition to emission control, the system also has multiple advanced operational strategies built-in:

Second gas type selection: allows the engine to switch between two different qualities of gas (such as natural gas and biogas), and the system automatically calls the corresponding control parameters.

Compressor demand signal: When the gas pressure is insufficient, it can automatically send a start signal to the booster compressor.

Engine preheating: Ensure that the engine reaches its optimal temperature before starting, reducing wear and emissions.