Analogue memory for value

storage
Using PLC and Force value

Application Sheet

Copyright © 2013 ComAp a.s. ComAp a.s.

Prague, Czech Republic Kundratka 2359/17
180 00 Prague 8
Czech Republic
E-mail: info@comap.cz, www.comap.cz
 1. Abstract
This application shows how to utilize PLC logic and Force value function to prepare analogue memory
which is refreshed by push button and can be used to store value at any given time. The source value may
be changing continuously but its original value (at the time when the button was pushed) is stored and used
for further functions.

This can be particularly useful when used in combination with Running Hours Equalization function. You
may prepare this function to write actual value of Running hours of each engine in a group into the
RunHoursBase setpoint when the corresponding button is pushed. This allows you to connect engine after
it was repaired and other engines have run for quite some time (e.g. 2000 hours). If you do not update
RunHoursBase at all engines the engine that has returned from the repairs will run continuously for 2000
hrs until its running hours are equal to the running hours of other gen-sets. If this is not desired you need to
update RunHoursBase at each engine and this application will show you how to do it automatically.

This application utilizes built-in internal PLC logic and Force value feature of ComAp controllers.

In the example below, you can see what happens when one the gen-sets is out of order for some time. It is
automatically assigned priority 1 when it comes back from repairs and it is always first to run for the next ca
2000 run hours (in our example). In this case, operator needs to change the RunHoursBase of the second
and third gen-set to prevent this from happening. This example shows you how to utilize built-in PLC and
force value function in ComAp controllers to perform RunHoursBase change at once with one push of a
button.

Run Hours = 1100 Run Hours = 1200 Run Hours = 1400

RunHrsBase = 100 RunHrsBase = 200 RunHrsBase = 400
RHE hours = 1000 RHE hours = 1000 RHE hours = 1000

In
Re
pa
irs

Run Hours = 1100 Run Hours = 2200 Run Hours = 2400

RunHrsBase = 100 RunHrsBase = 200 RunHrsBase = 400
RHE hours = 1000 RHE hours = 2000 RHE hours = 2000

Run Hours = 1100 Run Hours = 3200 Run Hours = 3400

RunHrsBase = 100 RunHrsBase = 200 RunHrsBase = 400
RHE hours = 1000 RHE hours = 3000 RHE hours = 3000
This gen-set is assigned priority 1 for
next ca 2000 running hours

-2-
VYDT
 2. List of controllers
NT NT NTC NT NT NTC
InteliGen , InteliGen BaseBox, InteliGen BaseBox, InteliSys , InteliSys BaseBox, InteliSys
NT NT NTC
BaseBox, InteliMains , InteliMains BaseBox, InteliMains BaseBox

3. List of tools
GenConfig

4. System schematic diagram(s)

1
2
3

-3-
VYDT
 5. Detailed description of solution
In this example normally open push button should be used to trigger the whole function. Wire that push
button to the binary input number 11 (or any other physical or virtual input, in this example number 11 is
used). Use PLC blocks as shown in the first figure. Block in area number one is Analogue Switch which
serves in this example as an actual analogue value storage memory. You should wire the analog value that
is changing but needs to be stored at the given time to the first input of this Ana Switch block (in our
example we have wired Running Hours statistic value to the first input of Ana Switch). Wire the output of
the Ana Switch to PLC output and name it (in our example, we have used the name RunHrsMemory).

In the second area, there is the binary input for triggering the function and one Delay block with variable
delay given by the PLC setpoint MemoryResetDel. This Delay prevents operator from unwanted reset of
the Running Hours if the button is accidentally pushed. MemoryResetDel in our example can be set to the
values from 0s to 60s.

Blocks in the third area are used to prevent invalid value of Run Hours to be stored in the memory when
the controller is switched on. There is block OR which has wired logical binary states of the controller to its
inputs (OFF mode, MAN mode and AUT mode). This block is used to produce signal of logical 1 on its
output once the controller is fully initialized and so only the correct value of the Run hours is stored and
non-initialized value of the memory is not stored. This causes the controller to Force value the actual
Running hours once it is switched on and then this value is stored in the memory.

As you can see the first binary input of the AND block is inverted. The inversion is there because the push
button connected to it is normally open and therefore the input will be normally closed. This is crucial for
the right function of this application.

Analogue Switch switches between two inputs and one of them is transferred to the output of this block. If
the I-SW input of Ana Switch is closed it sends input I2 signal to its output. If I-SW input gets inactive Ana
Switch sends input I1 signal to its output.

Once the input I-SW gets active (i.e. the push button is released and the controller is fully initialized) it will
switch to I2 input and therefore it will effectively store the current value of Run hours.

If the value needs to be refreshed (to level running hours of all engines in Running Hours Equalization
function) push button should be pushed and released to refresh the memory.

You may share the push button signal to all controllers on site to activate the refresh of the memory at once
in all controllers. Use SHBIN and SHBOUT (Shared Binary Inputs and Outputs) and prepare the same PLC
program and Force value function in all the controllers in Power management.

-4-
VYDT
Furthermore, you need to set Force value function to the corresponding setpoint (in this case to
RunHoursBase) and add corresponding force value trigged function to any VPIO input (Virtual Binary Input-
Output). This ensures that the setpoint RunHoursBase is forced all the time.

6. Example
The very basic example consists of three gen-sets (1, 2 and 3) with Run hours of 100, 200 and 400.
Running Hours Equalization function is required in this example.

The function described above is added to the configuration of all gen-set controllers. After uploading the
firmware, RunHoursBase is Force valued with the actual value of Run hours at the moment of controller
initialization. This means that RunHoursBase in the first controller is set to 100, in the second one to 200
and in the last one to 400. Running Hours Equalization function now considers all the gen-sets to have the
same Run hours and works accordingly to that.

Gen-sets are running for three months in RunningHoursEqualization (their Run hours climb to 2100, 2200
and 2400 respectively). After those three months first gen-set needs a repair so it is off duty for two
months. Run hours of gen-sets after these two additional months are 2100, 3200 and 3400. Repaired gen-
set is connected back and when the controller initializes, it is considered in Run Hours Equalization like it
has run for 0 hours (because RunHoursBase has updated to the value 2100). Other gen-sets on the other
hand are considered to have run for 3000 hours each (because of their stored RunHoursBase of 200 and
400). By pushing the button their RunHoursBase setpoints are updated as well and the Running Hours
Equalization system considers all gen-sets to have run for the same amount of hours. This prevents the
first gen-set from being assigned priority 1 for 2000 hours.

7. Other comments
This function is particularly useful if you do not want the new gen-set to run for e.g. 2000 hours before it
“catches up” with other gen-sets in the group. If this function was not utilized the gen-set from the example
above would run for more than 2000 hours before it would “catch up” with other two gen-sets and they
would start to take their turns.

Running hours in the Running Hours Equalization function are calculated as follows:

RHE_considered_RunHours = ActualRunningHours – RunHoursBase

For your convenience use the ComAp’s Starterkit to test the basic principle of this function: InteliGen NT
Colour StarterKit, InteliSys NT StarterKit.

Test this function in the full extent on one of the ComAp’s MultiKits: InteliGen NT Colour Multikit,
InteliSys NT MultiKit or H-System Multikit.

NOTE:
This function illustrates only one of many possible utilizations of Analog Memory in PLC function. Let us
know if you find some particularly interesting utilizations of this function.

-5-
VYDT