INTERFACE DESCRIPTION

MIP 4000 V2.2

CABLING & SOFTWARE COMMUNICATON
For Type Series 4000

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©2013 MTU Onsite Energy GmbH

Original document was created in German.

This publication including all its parts is protected by copyright. Each instance of use requires the prior written
consent of MTU Onsite Energy GmbH. This applies in particular to duplication, dissemination, editing,
translation, microfilming, and storage and/or processing in electronic systems, including databases and online
services.

Subject to technical alterations in the interest of further development.

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 Table of Contents

Table of Contents
Table of Contents ....................................................................................................................................................... 3
1 General .................................................................................................................................................... 7
1.1 Validity ...................................................................................................................................................... 7
2 Advantages - MIP 4000 .......................................................................................................................... 8
3 Scope of Service .................................................................................................................................... 9
4 Requirements of the Customer System ............................................................................................. 11
5 Hardware Signals ................................................................................................................................. 12
5.1 MIP - Digital inPuts ................................................................................................................................. 12
5.1.1 Emergency Stop of Customer System ................................................................................................... 12
5.1.2 GCB is On .............................................................................................................................................. 13
5.1.3 Grid failure from the Customer System .................................................................................................. 14
5.1.4 Checkback - Gas Valve 1 ....................................................................................................................... 16
5.1.5 Checkback - Gas Valve 2 ....................................................................................................................... 17
5.1.6 Checkback - Gas Pressure Min ............................................................................................................. 18
5.1.7 Checkback - Gas Pressure Max ............................................................................................................ 19
5.1.8 Checkback - Gas Leak Test OK............................................................................................................. 20
5.1.9 MCB is On .............................................................................................................................................. 21
5.2 MIP - Digital Outputs .............................................................................................................................. 22
5.2.1 Emergency Stop ..................................................................................................................................... 22
5.2.2 GCB Command Close ............................................................................................................................ 23
5.2.3 MCB Command Close ........................................................................................................................... 24
5.2.4 GCB Command Close ............................................................................................................................ 25
5.2.5 Backup Protection - GCB cannot be Opened ........................................................................................ 27
5.2.6 Request Auxiliary Drives ........................................................................................................................ 28
5.2.7 Request Lubricating Oil Solenoid Valves ............................................................................................... 29
5.2.8 Request Gas Leak Test ......................................................................................................................... 30
5.2.9 Request Gas Valve 1 ............................................................................................................................. 31
5.2.10 Request Gas Valve 2 ............................................................................................................................. 32
5.2.11 Checkback - Emergency Stop................................................................................................................ 33
5.3 MIP - Analog Inputs ................................................................................................................................ 34
5.3.1 Generator Winding Temperature - U1 ................................................................................................... 34
5.3.2 Generator Winding Temperature - V1 .................................................................................................... 34
5.3.3 Generator Winding Temperature - W1................................................................................................... 35
5.3.4 Generator Bearing Temperature - Drive Side ........................................................................................ 35
5.3.5 Generator Bearing Temperature - Non-Drive Side ................................................................................ 36
5.4 Manual Emergency Stop Buttons........................................................................................................... 36
5.5 MIP 4000 Supply Voltage - 24 VDC ....................................................................................................... 37
5.6 Ethernet Communication via RJ45 ........................................................................................................ 38
5.7 Generator Current Transformer 5 A ....................................................................................................... 39
5.8 Generator Voltage .................................................................................................................................. 40
5.9 Busbar Voltage ....................................................................................................................................... 41
5.10 Grid Voltage ........................................................................................................................................... 42
6 Generator - PFC and AVR .................................................................................................................... 43
6.1 Activation - Voltage Regulator................................................................................................................ 43
7 Generator Anti-Condensation Heating .............................................................................................. 44

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 Table of Contents

8 Overview - Cabling ............................................................................................................................... 45

9 Overview - Gas System ........................................................................................................................ 46
10 Software Signals................................................................................................................................... 47
10.1 Signals to the Customer System ............................................................................................................ 47
10.1.1 Request Pre-Lubrication ......................................................................................................................... 47
10.1.2 Request Engine Pre-Heating.................................................................................................................. 47
10.2 Signals from the Customer System ........................................................................................................ 48
10.2.1 Engine Start ............................................................................................................................................ 48
10.2.2 Reset ...................................................................................................................................................... 48
10.2.3 Enable Synchronization (GCB) .............................................................................................................. 49
10.2.4 Enable Synchronization (MCB) .............................................................................................................. 49
10.2.5 Higher Speed.......................................................................................................................................... 50
10.2.6 Lower Speed .......................................................................................................................................... 50
10.2.7 Grid Backup Mode Active ....................................................................................................................... 51
10.2.8 Black Start GCB ..................................................................................................................................... 51
10.2.9 Lack of Cooling Water ............................................................................................................................ 52
10.2.10 Setpoint - Effective Power ...................................................................................................................... 52
10.2.11 Black Start MCB ..................................................................................................................................... 53
11 Start- / Stop Procedure ........................................................................................................................ 54
11.1 Start Sequence ....................................................................................................................................... 54
11.2 Stop Sequence ....................................................................................................................................... 56
11.3 Emergency Stop Sequence .................................................................................................................... 57
11.4 Mains Parallel Operation ........................................................................................................................ 58
11.4.1 Engine Start ............................................................................................................................................ 58
11.4.2 Stopping the Engine ............................................................................................................................... 58
11.4.3 Grid Failure in Mains Parallel Operation ................................................................................................ 59
11.5 Grid Backup Mode .................................................................................................................................. 60
11.5.1 Engine is at a Standstill and a Grid Failure Occurs ................................................................................ 60
11.5.2 Operating Mode: Interruption at Grid Failure - Machine is running and a Grid Disturbance Occurs ..... 62
11.5.3 Operating Mode: No Interruption at Grid Failure - Machine is running and a Grid Disturbance Occurs 64
12 Software Communication .................................................................................................................... 66
12.1 General ................................................................................................................................................... 66
12.2 Data Protocol .......................................................................................................................................... 67
12.3 Alarm Messages ..................................................................................................................................... 68
12.4 Status Messages .................................................................................................................................... 68
12.5 Scaling of Values .................................................................................................................................... 69
12.6 Error Evaluation - External Communication ........................................................................................... 69
12.7 Ethernet (RJ45) with UDP Protocol - Standard ...................................................................................... 70
12.7.1 Presentation - UDP Protocol .................................................................................................................. 71
12.7.2 RFC 768 - Standard: User Datagram Protocol (UDP) ........................................................................... 72
13 Configuration and Service Wizard ...................................................................................................... 73

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 Table of Contents
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 General
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1 General
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MTU Onsite Energy is responsible for interface clarification between engine and customer system.
All interface signals between engine and customer system are operated by the MIP 4000.
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No. Description
A Genset
B Engine interface
C Customer interface
D Customer system controller
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1.1 Validity
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This document, Interface Description - MIP 4000 is valid from circuit diagram version and software version V2.2.0.0
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 Advantages - MIP 4000
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2 Advantages - MIP 4000

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 Complete design expertise through MTU Onsite Energy

 Interface changes on the motor side (MIS) will be handled by MTU Onsite Energy:
Minimal changes are required on the customer side.
 Customer desires (e.g. software communication) can be handled by MTU Onsite Energy.
 Software communication via Ethernet: „Bidirectional”.
 Complete genset and protection integrated in the MIP 4000 and MIS:
No guarantee restrictions.
 Synchronization of generator circuit breakers (GCB) is integrated in the MIP 4000.
 Synchronization of grid circuit breakers (MCB) integrated in the MIP 4000 - optional.
 Grid monitoring integrated in the MIP 4000:
(No protective function, without certificates for certain countries) - optional
 Remote access for MTU Onsite Energy possible: Better product support.
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 Scope of Service
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3 Scope of Service
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Communication with the Motor Interface Cabinet (MIS) via hardware signals and CAN Open.
Communication with the customer system via hardware signals and Ethernet.
Generator protection
 Generator overvoltage / generator undervoltage
 Generator over-frequency / generator under-frequency
 Generator overcurrent / generator undercurrent - stage 1 and stage 2
 Generator overload
 Generator reverse power
 Generator unbalanced load
Generator monitoring
 Generator effective power - P (kW)
 Generator reactive power - Q (kVAr)
 Generator apparent power – S (kVA)
 Generator frequency
 Generator voltage U12, U23, U31
 Generator current L1, L2, L3
 Generator cos phi
 Generator active energy (kWh)
Busbar monitoring
 Busbar voltage U12, U23, U31
 Busbar frequency
Grid monitoring
 Grid voltage U12, U23, U31
 Grid frequency
Synchronization
 Generator circuit breaker (GCB): Only floating contacts, power section in the customer system.
 Grid circuit breaker (MCB): Only floating contacts, power section in the customer system.
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 Scope of Service
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Generator temperature monitoring

 Winding temperature monitoring and protection
 Bearing temperature monitoring and protection
Gas system (monitoring and protection)
 Gas pressure min / max (protection)
 Activation of the gas leak test
 Activation of the gas valves
General control functions - without power sections (only floating contacts or software signals)
 Activation of the auxiliary drives
 Activation of the lubricating oil solenoid valves
 Activation of the pre-lubrication
 Activation of the engine pre-warming
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 Requirements of the Customer System
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4 Requirements of the Customer System

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Charging of the starter batteries

(external location of the starter system, see installation guideline)
Provision of 24 VDC power supply for the MIP 4000
(a power failure under 21 V is not allowed; maximum voltage is 28.8 V.
For rated voltage 24 VDC, 25 A must be made available).
Integration of safety relays (emergency stop buttons, safety transducers, etc.)
Integration of a grid protection device with the monitors
 Grid over-frequency / grid under-frequency
 Grid overvoltage / grid undervoltage
 Vector shift
 Asymmetry
 Phase shift monitoring
Optional integration of a differential protection device
Optional integration of a ground fault protection device
Provision of the power sections for
 Auxiliary drives
 Lubricating oil solenoid valves
 Fresh oil pump / old oil pump
 Pre-lubrication
 Engine pre-warming
 Generator circuit breaker
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 Hardware Signals
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5 Hardware Signals
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5.1 MIP - Digital inPuts

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5.1.1 Emergency Stop of Customer System

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B No emergency stop active

A Digital input
C Emergency stop active

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The machine will be stopped without delay. The auxiliary drives continue to remain activated.
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5.1.2 GCB is On
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B Generator circuit breaker (GCB) opened

A Digital input
C Generator circuit breaker (GCB) closed

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NOTICE
A fast, direct checkback is required from the generator circuit breaker (GCB).

SH-H-156
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5.1.3 Grid failure from the Customer System

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B No grid failure active

A Digital input
C Grid failure active

If a grid failure in grid backup operation is detected via this input, the generator circuit breaker (GCB) of the MIP
4000 will be opened.
Particularity in the event of grid disconnect via the grid circuit breaker (MCB) for uninterruptible grid
backup operation:
The grid disconnect via the grid circuit breaker (MCB) occurs through the customer system.
In this case the signal, "grid failure from the customer system" must not be activated, otherwise in grid backup
operation the generator circuit breaker (GCB) will be opened without delay and uninterruptible grid backup
operation is not possible.
For this mode it must be ensured that the grid disconnect is provided via the grid circuit breaker (MCB) in the
customer system.
Malfunction can cause damage to the machine and the generator.
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No. Description
001 Digital input
002 Customer system
Enable grid backup operation = contact closed:
003
Grid disconnect occurs through MCB in the customer system.
004 Grid monitoring device. Contact opens at grid failure.
005 Execution of pure grid backup operation or execution of grid backup operation with interruption.
Execution of grid backup mode without interruption.
006 Important: For this mode it must be ensured that the grid disconnect is provided via the grid circuit
breaker (MCB) in the customer system.
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 Hardware Signals
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5.1.4 Checkback - Gas Valve 1

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B Gas valve 1 closed

A Digital input
C Gas valve 1 open

After activation of the output "Request gas valve 1" this checkback must be signaled by the end position switch of
the gas valve.
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5.1.5 Checkback - Gas Valve 2

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B Gas valve 2 closed

A Digital input
C Gas valve 2 open

After activation of the output "Request gas valve 2" this checkback must be signaled by the end position switch of
the gas valve.
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 Hardware Signals
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5.1.6 Checkback - Gas Pressure Min

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B Gas pressure OK active

A Digital input
C Gas pressure < min active

The gas pressure switch "min" must be installed upstream of the gas valves.
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5.1.7 Checkback - Gas Pressure Max

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B Gas pressure OK active

A Digital input
C Gas pressure > max active

The gas pressure switch "max" must be installed upstream of the gas valves.
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 Hardware Signals
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5.1.8 Checkback - Gas Leak Test OK

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B Gas leak test OK active

A Digital input
C Gas leak test not OK active

After request for the gas leak test by the MIP 4000, this checkback must be signaled within an adjustable time (e.g.
30 s, parameter is assigned in the MIP 4000) otherwise the start procedure will be interrupted.
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5.1.9 MCB is On
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B Main circuit breaker (MCB) open

A Digital input
C Main circuit breaker (MCB) closed

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NOTICE
A fast, direct checkback is required from the main circuit breaker (MCB).

SH-H-158
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 Hardware Signals
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5.2 MIP - Digital Outputs

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5.2.1 Emergency Stop

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Max. contact current capacity: B Emergency stop active

 24 VDC 10 A
A
 220 VDC 0.22 A
 230 VAC 6 A C No emergency stop active

In the event of an active emergency stop the generator circuit breaker (GCB) will be opened automatically by the
MIP 4000.
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5.2.2 GCB Command Close

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Max. contact current capacity: B No "close" command is active

 24 VAC 8 A
A
 220 VDC 0.12 A
 230 VAC 8 A C "Close" command is active

After satisfying the connection requirements the MIP 4000 outputs a close pulse for the generator circuit breaker
(GCB). Parameters can be assigned for the pulse length of the close contact (standard: 250 milliseconds).
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5.2.3 MCB Command Close

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Max. contact current capacity: B No "close" command is active

 24 VAC 8 A
A
 220 VDC 0.12 A
 230 VAC 8 A C "Close" command is active

After satisfying the connection requirements the MIP 4000 outputs a close pulse for the main circuit breaker (MCB).
Parameters can be assigned for the pulse length of the close contact (standard: 250 milliseconds).
This signal is required for a grid backup system for the return-synchronization of the MCB.
A black start for the MCB is possible from MIP 4000 version 2.
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Pos : 67 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-GLS Befehl öffnen @ 7\mod_1263911051305_433021.doc x @ 436183 @ 3 @ 1

5.2.4 GCB Command Close

Pos : 68 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 004 @ 7\mod_1263911134461_433021.doc x @ 436184 @ @ 1

 Switch with undervoltage tripping device (UTD)

No. Description
Max. contact current capacity:
 24 VDC 5.8 A
A
 220 VDC 0.12 A
 230 VAC 6 A
001 GCB "open" command active
002 No GCB "open" command active
Pos : 69 /OX-Seitenumbruc h @ 0 \mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 70 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 005 @ 7\mod_1263911284756_433021.doc x @ 436185 @ @ 1

 Switch with undervoltage tripping device (UTD) and work current tripping device (WCTD)

No. Description
Max. contact current capacity:
 24 VDC 5.8 A
A
 220 VDC 0.12 A
 230 VAC 6 A
001 GCB "open" command active
002 No GCB "open" command active
Pos : 71 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 006 @ 7\mod_1263911378318_433021.doc x @ 436186 @ @ 1

The GCB will be opened by the MIP 4000 at the conditions specified below:

No. Description
1 A generator protection monitor has been activated.
1 Input "grid failure from the customer system" has been opened in grid backup mode.
In grid backup mode the software signal "engine start" has been reset and the electrical power
2
drops below a minimum value for which parameters can be assigned (default: 1%).
2 Red alarm (immediate stop) without ramp active.
Red alarm (controlled stop) with ramp active.
2
Electrical power drops below a minimum value for which parameters can be set (default: 1%).
2 Software signal "enable synchronization GCB" has been reset.
Pos : 72 /OX-Seitenumbruc h @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

26 DK-SB-0002 / V03 / 08.04.2013

 Hardware Signals
Pos : 73 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Bac kupschutz @ 7\mod_1263911916627_433021.doc x @ 436187 @ 3 @ 1

5.2.5 Backup Protection - GCB cannot be Opened

Pos : 74 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 007 @ 7\mod_1263994977827_433021.doc x @ 436194 @ @ 1

Max. contact current capacity: B No backup protection active

 24 VDC 5.8 A
A
 220 VDC 0.18 A
 230 VAC 6 A C Backup protection active

Backup protection is activated when the generator circuit breaker (GCB) cannot be opened by the MIP 4000. In this
case the customer system controller must open a higher-level switch.
Pos : 75 /OX-Seitenumbruc h @ 0 \mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 76 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Anforderung Hilfs antriebe @ 7\mod_1263994247926_433021.doc x @ 436188 @ 3 @ 1

5.2.6 Request Auxiliary Drives

Pos : 77 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 008 @ 7\mod_1263995128404_433021.doc x @ 436195 @ @ 1

Max. contact current capacity: B No request

 24 VDC 5.8 A
A
 220 VDC 0.18 A
 230 VAC 6 A C Request for auxiliary drives active

The contact is closed at a start command and will only be opened when the engine is at a standstill and the
afterrun time has elapsed.
The customer system controller must activate the appropriate auxiliary drives (pumps, room ventilation, etc.).
Pos : 78 /OX-Seitenumbruc h @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 79 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Anforderung Schmi eröl magnetventil e @ 7\mod_1263994301785_433021.doc x @ 436189 @ 3 @ 1

5.2.7 Request Lubricating Oil Solenoid Valves

Pos : 80 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 009 @ 7\mod_1263995263463_433021.doc x @ 436196 @ @ 1

Max. contact current capacity: B No request

 24 VDC 5.8 A
A
 220 VDC 0.18 A
 230 VAC 6 A C Request for top up active

The request for the lubricating oil solenoid valves is activated, if the oil top-up trips due to reduced oil level. The
machine must be in operation for at least 5 minutes.
If the request for the lubricating oil solenoid valves is set too often, an alarm becomes active. The request is
activated in a pulse/pause ratio (adjustable in the MIP 4000). The oil is topped up via a fresh oil pump or from a
fresh oil tank in the appropriate installed height.
Pos : 81 /OX-Seitenumbruc h @ 0 \mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 82 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Anforderung Gas dichtheits tes t @ 7\mod_1263994401753_433021.doc x @ 436190 @ 3 @ 1

5.2.8 Request Gas Leak Test

Pos : 83 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 010 @ 7\mod_1263995634733_433021.doc x @ 436197 @ @ 1

Max. contact current capacity: B No request

 24 VAC 8 A
A
 220 VDC 0.12 A
 230 VAC 8 A C Request gas leak test active

The request is activated at every start.

Pos : 84 /OX-Seitenumbruc h @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

30 DK-SB-0002 / V03 / 08.04.2013

 Hardware Signals
Pos : 85 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Anforderung Gas magnetventil 1 @ 7\mod_1263994457503_433021.doc x @ 436191 @ 3 @ 1

5.2.9 Request Gas Valve 1

Pos : 86 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 011 @ 18\mod_1332508235492_433021.doc x @ 535325 @ @ 1

Max. contact current capacity: B No request

 24 VAC 20 A
A
 110 VDC 0.15 A
 400 VAC 9 A C Request gas valve 1 active

With request the gas valve 1 must open.

Pos : 87 /OX-Seitenumbruc h @ 0 \mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 88 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Anforderung Gas magnetventil 2 @ 7\mod_1263994509783_433021.doc x @ 436192 @ 3 @ 1

5.2.10 Request Gas Valve 2

Pos : 89 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 012 @ 18\mod_1332508446892_433021.doc x @ 535354 @ @ 1

Max. contact current capacity: B No request

 24 VAC 20 A
A
 250 VDC 0.5 A
 440 VAC 12 A C Request gas valve 2 active

With request the gas valve 2 must open.

Pos : 90 /OX-Seitenumbruc h @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

32 DK-SB-0002 / V03 / 08.04.2013

 Hardware Signals
Pos : 91 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Rüc kmel dung NOT-HALT @ 18\mod_1332508884643_433021.doc x @ 535412 @ 3 @ 1

5.2.11 Checkback - Emergency Stop

Pos : 92 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 015 @ 18\mod_1332509158072_433021.doc x @ 535441 @ @ 1

Max. contact current capacity: B Emergency stop active

 24 VDC 10 A
A
 220 VDC 0.22 A
 230 VAC 6 A C No emergency stop active

This signal indicates the status of the emergency stop of the customer system.
The signal is intended for the return circuit of the emergency stop customer system controller.
Pos : 93 /OX-Seitenumbruc h @ 0 \mod_1218433559331_0.doc x @ 441052 @ @ 1

DK-SB-0002 / V03 / 08.04.2013 33

 Hardware Signals
Pos : 94 /D okumentation/Ü B-Übersc hriften/1.1/Ü B-MIP Analoge Ei ngänge @ 7\mod_1263996826207_433021.doc x @ 436202 @ 2 @ 1

5.3 MIP - Analog Inputs

Pos : 95 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Generator wic kl ungstemperatur U 1 @ 7 \mod_1263997569874_433021.doc x @ 436206 @ 3 @ 1

5.3.1 Generator Winding Temperature - U1

Pos : 96 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 013 @ 7\mod_1263995922595_433021.doc x @ 436200 @ @ 1

 Cabled in the MIP 4000 scope of delivery!

Pos : 97 /D okumentation/Beschr eibung/SB/MI P 4000/T X-MIP Anal oge Eing äng e-001 @ 7\mod_1263996962456_433021.doc x @ 436203 @ @ 1
*/

The generator winding temperature U1 can be designed as PT1000 or PT100 and is monitored for limit value
overshoot and wire break.
Pos : 98 /D okumentation/Ü B-Übersc hriften/1.1.1/Ü B-Generator wic kl ungstemperatur V1 @ 7\mod_1263997649014_433021.doc x @ 436207 @ 3 @ 1
2

5.3.2 Generator Winding Temperature - V1

Pos : 99 /D okumentation/Beschr eibung/SB/MIP 4000/T X-MIP Digitale Ausgänge- 013 @ 7\mod_1263995922595_433021.doc x @ 436200 @ @ 1

 Cabled in the MIP 4000 scope of delivery!

Pos : 100 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Analog e Eingänge- 002 @ 7\mod_1263997163908_433021.doc x @ 436204 @ @ 1

The generator winding temperature V1 can be designed as Pt1000 or Pt100 and is monitored for limit value
overshoot and wire break.
Pos : 101 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

34 DK-SB-0002 / V03 / 08.04.2013

 Hardware Signals
Pos : 102 /Dokumentati on/ÜB-Ü berschriften/1.1.1/Ü B-Generator wic kl ungstemper atur W1 @ 7\mod_1263997717733_433021.doc x @ 436208 @ 3 @ 1

5.3.3 Generator Winding Temperature - W1

Pos : 103 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Digital e Ausgänge-013 @ 7\mod_1263995922595_433021.doc x @ 436200 @ @ 1

 Cabled in the MIP 4000 scope of delivery!

Pos : 104 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Analog e Eingänge- 003 @ 7\mod_1263997396422_433021.doc x @ 436205 @ @ 1

The generator winding temperature W1 can be designed as PT1000 or PT100 and is monitored for limit value
overshoot and wire break.
Pos : 105 /Dokumentati on/ÜB-Ü berschriften/1.1.1/Ü B-Generatorlag ertemperatur Antriebssei te @ 7\mod_1263997998465_433021.doc x @ 436209 @ 3 @ 1

5.3.4 Generator Bearing Temperature - Drive Side

Pos : 106 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Digital e Ausgänge-013 @ 7\mod_1263995922595_433021.doc x @ 436200 @ @ 1

 Cabled in the MIP 4000 scope of delivery!

Pos : 107 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Analog e Eingänge- 004 @ 7\mod_1263998619877_433021.doc x @ 436210 @ @ 1

The generator winding temperature - drive side - can be designed as PT1000 or PT100 and is monitored for limit
value overshoot and wire break.
Pos : 108 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

DK-SB-0002 / V03 / 08.04.2013 35

 Hardware Signals
Pos : 109 /Dokumentati on/ÜB-Ü berschriften/1.1.1/Ü B-Generatorlag ertemperatur Nic htantriebssei te @ 7\mod_1264069585386_433021.doc x @ 436215 @ 3 @ 1

5.3.5 Generator Bearing Temperature - Non-Drive Side

Pos : 110 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Digital e Ausgänge-013 @ 7\mod_1263995922595_433021.doc x @ 436200 @ @ 1

 Cabled in the MIP 4000 scope of delivery!

Pos : 111 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Analog e Eingänge- 005 @ 7\mod_1264068165447_433021.doc x @ 436211 @ @ 1

The generator winding temperature - non-drive side - can be designed as Pt1000 or Pt100 and is monitored for
limit value overshoot and wire break.
Pos : 112 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Hand-N OT-HALT-Tas ter @ 7\mod_1264068428227_433021.doc x @ 436212 @ 2 @ 1

5.4 Manual Emergency Stop Buttons

Pos : 113 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-H andnotaustaster-001 @ 7\mod_1264069129800_433021.doc x @ 436213 @ @ 1

A manual emergency stop button is attached on the MIP 4000.

The customer system controller must integrate this emergency stop switch in a tested safety chain.
By activating the emergency stop button the safety chain must be tripped without delay.
The digital "emergency stop from customer system" must also be opened.
Pos : 114 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 115 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-MIP 4000 Versorgungsspannung 24 VDC @ 7\mod_1264069498427_433021.doc x @ 436214 @ 2 @ 1

5.5 MIP 4000 Supply Voltage - 24 VDC

Pos : 116 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Vers orgungss pannung 24 VDC- 001 @ 7\mod_1264069922532_433021.doc x @ 436217 @ @ 1

A voltage drop under 21 VDC is not permitted; the maximum permissible voltage is 28.8 VDC.
It must be provided at rated voltage 24 VDC 25 A.
Pos : 117 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 118 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Ethernet-Kommuni kation über R J45 @ 7\mod_1264069815616_433021.doc x @ 436216 @ 2 @ 1

5.6 Ethernet Communication via RJ45

Pos : 119 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Ether net-Kommuni kation über RJ 45-001 @ 7\mod_1264070020934_433021.doc x @ 436218 @ @ 1

No. Description
001 Crossed cable - CAT5
002 Customer CPU

For direct cabling: Use CAT5, crossed cable

No. Description
001 Switch
002 Customer CPU
003 1:1 cable CAT5

Cabling via switch: Use CAT5, 1:1 cable

Pos : 120 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 121 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Generatorstr ommes s wandler 5 A @ 7\mod_1264070231584_433021.doc x @ 436219 @ 2 @ 1

5.7 Generator Current Transformer 5 A

Pos : 122 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Digital e Ausgänge-013 @ 7\mod_1263995922595_433021.doc x @ 436200 @ @ 1

 Cabled in the MIP 4000 scope of delivery!

Pos : 123 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Gener atorstrommess wandl er-001 @ 7\mod_1264070455283_433021.doc x @ 436221 @ @ 1

The current transformer terminals K are only grounded at a voltage greater than 1 kV.
Version 5 A or 1 A can be used as generator current transformers. Standard is 5 A.
If the current transformer is changed from 5 A to 1 A, cabling and parameters must be adapted in the MIP 4000.
The generator current converters are used to calculate the electrical effective power and for generator protection.
Pos : 124 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 125 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Generators pannung @ 7\mod_1264070310645_433021.doc x @ 436220 @ 2 @ 1

5.8 Generator Voltage

Pos : 126 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Gener atorspannung-001 @ 7\mod_1264070609624_433021.doc x @ 436224 @ @ 1

Version 400 VAC or 100 VAC can be used as generator voltage.

If the measurement voltage is changed from 400 VAC to 100 VAC, the parameters in the MIP 4000 must be
adjusted.
The generator voltage is used to synchronize the generator circuit breaker (GCB) and for generator protection.
 Synchronization - GCB: Busbar voltage ↔ generator voltage
Pos : 127 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 128 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Sammelsc hienens pannung @ 7\mod_1264070885198_433021.doc x @ 436226 @ 2 @ 1

5.9 Busbar Voltage

Pos : 129 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Sammelsc hienens pannung-001 @ 7\mod_1264070757512_433021.doc x @ 436225 @ @ 1

Version 400 VAC or 100 VAC can be used as busbar voltage.

If the measurement voltage is changed from 400 VAC to 100 VAC, the parameters in the MIP 4000 must be
adjusted.
The busbar voltage is used to synchronize the generator circuit breaker (GCB) and for the grid circuit breaker
(MCB).
 Synchronization GCB: Busbar voltage ↔ generator voltage
 Synchronization MCB: Busbar voltage ↔ grid voltage
Pos : 130 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Hardware Signals
Pos : 131 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Netzspannung @ 7\mod_1264070978400_433021.doc x @ 436227 @ 2 @ 1

5.10 Grid Voltage

Pos : 132 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-N etzs pannung-001 @ 7\mod_1264071052727_433021.doc x @ 436228 @ @ 1

Version 400 VAC or 100 VAC can be used as grid voltage.

If the measurement voltage is changed from 400 VAC to 100 VAC, the parameters in the MIP 4000 must be
adjusted.
The grid voltage is used to synchronize the grid circuit breaker (MCB).
 Synchronization MCB: Busbar voltage ↔ grid voltage
Pos : 133 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Generator - PFC and AVR
Pos : 134 /Dokumentati on/ÜB-Ü berschriften/1/Ü B-Generator PFC und AVR @ 7\mod_1264071282553_433021.doc x @ 436229 @ 1 @ 1

6 Generator - PFC and AVR

Pos : 135 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Gener ator PFC und AVR- 001 @ 18\mod_1334065105079_433021.doc x @ 536088 @ @ 1

The generator is equipped with a voltage regulator and a cos phi regulator (AVR and PFC).
The connection between cos phi regulator (PFC) and voltage regulator (AVR) is disconnected. Thus the cos phi
regulator no longer has a function. The voltage regulator (AVR) gets the setpoint via an analog output of the MIP.
Pos : 136 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Ansteuerung Spannungssr egler @ 18\mod_1332744899858_433021.doc x @ 535537 @ 2 @ 1

6.1 Activation - Voltage Regulator

Pos : 137 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-MIP Digital e Ausgänge-013 @ 7\mod_1263995922595_433021.doc x @ 436200 @ @ 1

 Cabled in the MIP 4000 scope of delivery!

Pos : 138 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Ans teuerung Spannungsregler-001 @ 18\mod_1334065657870_433021.doc x @ 536117 @ @ 1

The voltage and the cos phi can be variably changed by the MIP. The MIP regulates the voltage or the cos phi of
the generator with an analog signal. The setpoints for the regulator and the appropriate control parameters can be
set via the MIP.
Pos : 139 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Generator Anti-Condensation Heating
Pos : 140 /Dokumentati on/ÜB-Ü berschriften/1/Ü B-Generatorstillstandsheizung @ 7 \mod_1264082109991_433021.doc x @ 436235 @ 1 @ 1

7 Generator Anti-Condensation Heating

Pos : 141 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Gener atorstillstands heiz ung -001 @ 7\mod_1264082378216_433021.doc x @ 436237 @ @ 1

The generator is equipped with a heater (230 VAC, fuse: B6A).

This heater must be activated under the following conditions:
 Generator circuit breaker GCB opened
 and machine at a standstill.
The cabling is not included in the MIP 4000: Execution occurs in the customer system!
Pos : 142 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

44 DK-SB-0002 / V03 / 08.04.2013

 Overview - Cabling
Pos : 143 /Dokumentati on/ÜB-Ü berschriften/1/Ü B-Übersicht Ver kabelung @ 7\mod_1264084128083_433021.doc x @ 436238 @ 1 @ 1

8 Overview - Cabling
Pos : 144 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-Ü bersic ht Ver kabelung-001 @ 8\mod_1265724658300_433021.doc x @ 436390 @ @ 1

No. Description
A Remote access (DSL)
B Customer system controller
Pos : 145 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-Ü bersic ht Ver kabelung-002 @ 8\mod_1265724759486_433021.doc x @ 436391 @ @ 1

No. Description
A Customer interface
A Grid voltage, generator voltage, busbar voltage (100 VAC or 400 VAC)
A 24 VDC supply
A Software communication (Ethernet)
A Checkbacks / specifications (from the customer)
A Requests (to the customer)
B Generator
B Generator current transformers (1 A or 5 A)
B Winding temperatures (U, V, W)
B Bearing temperatures
B Generator anti-condensation heater (230 VAC)
Pos : 146 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Overview - Gas System
Pos : 147 /Dokumentati on/ÜB-Ü berschriften/1/Ü B-Übersicht Gass ystem @ 7\mod_1264084483909_433021.doc x @ 436239 @ 1 @ 1

9 Overview - Gas System

Pos : 148 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX-Ü bersic ht Gass ys tem- 001 @ 8\mod_1265725200731_433021.doc x @ 436392 @ @ 1

No. Description
001 Customer
002 Checkback - gas valve V1 (open)
003 Checkback - gas pressure min.
004 Checkback - leak test OK
005 Request leak test
006 Checkback - gas valve V2 (open)
007 Checkback - gas pressure max.
Pos : 149 /OX-Seitenumbr uch @ 0\mod_1218433559331_0.doc x @ 441052 @ @ 1

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 Software Signals
Pos : 150 /Dokumentati on/ÜB-Ü berschriften/1/Ü B-Softwaresig nal e @ 7\mod_1264084604642_433021.doc x @ 436240 @ 1 @ 1

10 Software Signals
Pos : 151 /Dokumentati on/ÜB-Ü berschriften/1.1/Ü B-Signale zur Kundenanl age @ 7\mod_1264084686283_433021.doc x @ 436241 @ 2 @ 1

10.1 Signals to the Customer System

Pos : 152 /Dokumentati on/ÜB-Ü berschriften/1.1.1/Ü B-Anfor derung Vorschmi erung @ 7\mod_1264085043155_433021.doc x @ 436244 @ 3 @ 1

10.1.1 Request Pre-Lubrication

Pos : 153 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Signal e z ur Kundenanl age-001 @ 7\mod_1264084936734_433021.doc x @ 436243 @ @ 1

High signal: Request pre-lubrication

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10.1.2 Request Engine Pre-Heating

Pos : 155 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Signal e z ur Kundenanl age-002 @ 7\mod_1264085216373_433021.doc x @ 436246 @ @ 1

High signal: Request engine pre-heating

The request for engine pre-heating is set depending on the engine cooling water exit temperature.
The engine pre-warming is activated when the temperature limit value is underranged.
The customer system controller must activate the cooling water pump, so that a cooling water differential pressure
of 0.7 bar is built up after 10 seconds.
If this differential pressure is not built up the alarm "fault engine oil pre-warming" will be output and the request for
engine oil pre-warming will be reset.
After a time for which parameters can be assigned, the request for engine pre-warming will be reactivated.
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10.2 Signals from the Customer System

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10.2.1 Engine Start

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High signal: Start command

Low signal: No start command, stop procedure is activated.

To enable grid backup mode, in addition the "grid backup mode active" signal is required.
Pos : 160 /Dokumentati on/Sic herheit/SH-Sic her heitshi nweise/SH-Hinweis/SH-H-159 @ 13\mod_1307436906137_433021.doc x @ 448553 @ @ 1

NOTICE
The start procedure will not be executed if stop messages from the engine (red alarm) are

SH-H-159
active.
The start procedure will not be executed if the digital input "emergency stop from customer
system" is activated.

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10.2.2 Reset
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High signal: To acknowledge active alarms, a pulse with a pulse length of at least 1 second is expected.
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10.2.3 Enable Synchronization (GCB)

Pos : 165 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Signal e von Kundenanlag e-003 @ 7\mod_1264164108777_433021.doc x @ 436252 @ @ 1

High signal: Enable synchronization

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After the machine has reached rated speed and is stabilized, synchronization will be started with the signal "enable
synchronization (GCB).
The triggered synchronization can also be stopped again by the customer system controller by setting the signal to
low.
If this signal is reset while the generator circuit breaker (GCB) is closed, then the GCB will be opened.
Pos : 167 /Dokumentati on/ÜB-Ü berschriften/1.1.1/Ü B-Freigabe Sync hronisier ung (N LS) @ 7\mod_1264165033835_433021.doc x @ 436255 @ 3 @ 1

10.2.4 Enable Synchronization (MCB)

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 Is only required for a grid backup system!

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High signal: Enable synchronization (MCB)

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The machine is in grid backup mode (GCB is closed, MCB is opened), no grid failure is active:
The return synchronization of the MCB will be triggered with the signal "enable synchronization (MCB)".
This sequence corresponds to the return synchronization without interruption.
The triggered synchronization can also be stopped again by the customer system controller by setting the signal to
low.
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10.2.5 Higher Speed

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High signal: Higher speed (minimum pulse length 100 ms)

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In grid backup mode the speed specification can be influenced by the customer system controller.
This is typically used for effective load distribution in isolated parallel operation or for return synchronization of
higher-level circuit breakers.
The engine speed is increased automatically if this signal is activated.
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10.2.6 Lower Speed

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High signal: Lower speed (minimum pulse length 100 ms)

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In grid backup mode the speed specification can be influenced by the customer system controller.
This is typically used for effective load distribution in isolated parallel operation or for return synchronization of
higher-level circuit breakers.
The engine speed is decreased automatically if this signal is activated.
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10.2.7 Grid Backup Mode Active

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 Is only required for a grid backup system!

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High signal: Grid backup mode is activated.

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To enable grid backup mode this signal must be activated.

To trigger grid backup mode, in the event of grid failure the signal, "grid backup mod active" and "engine start" are
used as the start command.
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Additional functions:
If grid backup mode is triggered by engine standstill, then the auxiliary drives (cooling water pump, etc.) will not be
supplied for certain time due to a lack of generator voltage / busbar voltage.
Consequently with this signal, certain alarms will be delayed for parameter-assignable time, to prevent engine shut-
off due to temperature monitors / pressure monitors.
Pos : 184 /Dokumentati on/ÜB-Ü berschriften/1.1.1/Ü B-Sc hwarzs tart GLS @ 7\mod_1264165521567_433021.doc x @ 436259 @ 3 @ 1

10.2.8 Black Start GCB

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 Is only required for a grid backup system!

Pos : 186 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Signal e von Kundenanlag e-015 @ 7\mod_1264168161949_433021.doc x @ 436273 @ @ 1

High signal: Black start GCB active

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The following conditions must be satisfied to close the generator circuit breaker (GCB) without synchronization:
 Busbar is de-energized.
 MCB is open.
 GCB is open.
 Signal "enable synchronization (GCB)" is activated.
 Signal "black start GCB" is activated.
 The machine has reached rated speed and is stabilized.
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10.2.9 Lack of Cooling Water

Pos : 190 /Dokumentati on/Besc hrei bung/SB/MIP 4000/TX- Signal e von Kundenanlag e-017 @ 7\mod_1264168765762_433021.doc x @ 436275 @ @ 1

High signal: There is a lack of cooling water

The cooling water level drops under minimum. The machine will be stopped.
Pos : 191 /Dokumentati on/ÜB-Ü berschriften/1.1.1/Ü B-Sollwert Wir kleis tung @ 7\ mod_1264165619285_433021.doc x @ 436261 @ 3 @ 1

10.2.10 Setpoint - Effective Power

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Range: 0.0 to 100.0%

In grid backup mode a setpoint is expected for the electrical effective power.
After the GCB is closed, the power ramp becomes active.
The parameters of the power ramp (load / offload in % / s) can be set in the MIP 4000.
A power ramp is not required in the customer system.
Monitor - minimum power:
It is not permitted to operate the machine for a longer period of time under minimum power (default is 30%).
If the external setpoint is specified under this minimum power, then after a period of time, the alarm "LO minimum
load" will be active.
In this case the customer system must then specify a setpoint above the minimum power.
Stop activated:
At an activated stop the setpoint must not be set to 0%. Offloading of the power ramp will be executed
automatically by the MIP 4000.
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10.2.11 Black Start MCB

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 Is only required for a grid backup system!

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 Possible from MIP 4000 version 2!

High signal: Black start MCB active

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The following conditions must be satisfied to close the main circuit breaker (MCB) without synchronization:
 Busbar is de-energized.
 MCB is open.
 GCB is open.
 Signal "enable synchronization (MCB)" is activated.
 Signal "black start MCB" is activated.
 No grid failure active
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11 Start- / Stop Procedure

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11.1 Start Sequence

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 Grid backup mode:

Start command with signal "engine start"
No engine stop message (red alarm) is active
 Grid backup mode:
Start preconditions 1
If there is a grid fault "start command", the signal
"grid backup mode active", and "engine start" are
required to trigger grid backup mode.
 No engine stop message (red alarm) is active

No start

 Activate auxiliary drives with signal "request

auxiliary drives".
Phase 1
 Start gas leak test with signal "request gas leak
test".

 Gas leak test OK with signal "checkback gas leak

Start preconditions 2
test OK.

Start abort

 Gas valves open with signal "request gas valve 1"

Phase 2
and "request gas valve 2".

Concerning start condition 3

54 DK-SB-0002 / V03 / 08.04.2013

 Start- / Stop Procedure

 Gas valves are opened with signal "checkback gas

Start preconditions 3
valve 1" and "checkback gas valve 2".

Start abort

 Rated speed is reached

 Monitoring of generator voltage and generator
Phase 3
frequency
 Activate run-on time for auxiliary drives

 (Generator voltage > limit value) and (Generator

Start preconditions 4
frequency > limit value)

Start abort

 Enable synchronization GCB with signal "enable

synchronization (GCB)"
Phase 4  In addition grid backup mode and de-energized
busbar the signal "black start GCB" is also
required.

 Generator circuit breaker must be on and the time

Start preconditions 5
monitor must not yet have elapsed

Start abort

Grid parallel: Monitoring of power

regulation, ramp
Island operation: Activate island
mode (frequency controller)
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 Start- / Stop Procedure
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11.2 Stop Sequence

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Genset in operation and stop pending.

Stop at:
 Signal "engine start" has been reset (controlled
Phase 0
stop)
 Red alarm via ramp (controlled stop)
 Red alarm without ramp (immediate stop)

 Slow stop (ramp function) or

Stop condition 0
 Fast stop (open switch)

Fast stop: Jump to phase 2 immediately

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

Stop condition 1  Minimum power underranged

Remains in phase 1

To phase 2

56 DK-SB-0002 / V03 / 08.04.2013

 Start- / Stop Procedure

 Open generator circuit breaker with signal "GCB

open".
 Activate speed control.
Phase 2  Gas valves close with signal "request gas valve 1"
and "request gas valve 2".
 Start afterrun time for auxiliary drives (signal
"request auxiliary drives)

Genset ready to start

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11.3 Emergency Stop Sequence

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Genset in operation and emergency stop pending.

Emergency stop if:
 Emergency stop button has been activated
Phase 1
 Emergency stop of the engine is active
 Signal "emergency stop from customer system" is
activated.

Gas valves close with signal

"request gas valve 1" and "request
gas valve 2".
Open generator circuit breaker
with signal "GCB command open".
Activate speed control.
Start afterrun time for auxiliary
drives (signal "request auxiliary
drives).
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11.4 Mains Parallel Operation

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11.4.1 Engine Start

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1. To start, the signal "engine start" must be set to high.

2. After the genset has reached the rated speed, the signal, "enable GCB" must be set to high.
The generator circuit breaker will then be synchronized. The triggered synchronization can also be
stopped again by the customer system controller by setting the signal to low.
If this signal is reset when the generator circuit breaker (GCB) is closed, then the GCB opens.
3. After the generator circuit breaker closes mains parallel operation is immediately active.
The electrical effective power is specified via the signal, "setpoint effective power".
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11.4.2 Stopping the Engine

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1. In mains parallel operation, the signal "engine start" must be set to low. The engine will now be
offloaded via power ramp.
Important: The signal "enable synchronization (GCB)" must continue to remain on high, otherwise
the generator circuit breaker GCB will be activated.
2. With a parameter-assignable power value (default 1%) the generator circuit breaker GCB will be
opened.
After the generator circuit breaker has been opened, the signal, "enable GCB" must be set to low.
The engine will be stopped.
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11.4.3 Grid Failure in Mains Parallel Operation

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The following procedure applies when grid backup mode is not enabled via the signal "grid backup mode active".

1. In mains parallel operation the signals "engine start" and "enable GCB" are set to high.
A grid failure is detected via the signal "grid failure from customer system".
The generator circuit breaker (GCB) will be opened.
2. If this only involves a brief interruption (SI), then the generator circuit breaker GCB will connected
resynchronized.
If an actual grid failure is involved the engine will be stopped.
After the grid failure has ended, the grid stabilization timer is started (adjustable timer). After the grid
stabilization timer has elapsed, the engine is enabled.
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11.5 Grid Backup Mode

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11.5.1 Engine is at a Standstill and a Grid Failure Occurs

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 Signal "engine start" = high

 Signal "enable GCB" = low
Machine is at a standstill
phase 0  Grid backup enabled via signal "enable grid backup
mode" (= high).
 The engine will be started.

 If the rated speed is reached, the grid circuit

Machine is at a standstill
breaker (MCB) must be opened by the customer
phase 1
system controller.

 If both switches (GCB and MCB) are opened, the

generator circuit breaker will be switched to de-
energized busbar, if the signal "enable
synchronization (GCB)" (= high) and "black start
Machine is at a standstill
GCB" (= high) is activated.
phase 2
If the busbar is not de-energized, because it is
already supplied by a different genset, the
generator circuit breaker will be connected
synchronized.

Concerning machine is at a
standstill
phase 3

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 Start- / Stop Procedure

 Grid backup mode is active if the grid circuit

breaker GCB is open and the generator circuit
breaker (GLS) is closed => frequency regulation in
Machine is at a standstill the MIP 4000 is activated.
phase 3
 Via the signals "higher speed" and "lower speed"
load balancing can be executed in island parallel
mode with multiple engines.

Mode
interruption at grid failure

No interruption at grid failure

Machine running
phase 2

No interruption at grid failure

Machine running
phase 4
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11.5.2 Operating Mode: Interruption at Grid Failure - Machine is running and a Grid
Disturbance Occurs
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 Signal "engine start" = high

 Signal "enable synchronization (GCB)" = high
 Grid backup enabled via signal "grid backup
Machine running
operation active" (= high).
phase 0
 Grid failure active via the signal "grid failure from
customer system":
 Generator circuit breaker will be opened.

 Generator circuit breaker (GCB) is opened. If this

only involves a brief interruption (SI), then the
generator circuit breaker GCB will connected
Machine running resynchronized.
phase 1
 If a real grid failure is involved, the grid circuit
breaker (MCB) must be opened by the customer
system controller.

 If both switches (GCB + MCB) are opened, the

generator circuit breaker will be switched to de-
energized busbar, if the signal "enable
synchronization (GCB)" (= high) and "black start
Machine running
GCB" (= high) is activated.
phase 2
If the busbar is not de-energized, because it is
already supplied by a different genset, then the
generator circuit breaker will be connected
synchronized.

 Grid backup mode is active if the grid circuit

breaker MCB is open and the generator circuit
breaker (GCB) is closed: Frequency regulation in
Machine running the MIP 4000 is activated.
phase 3
 Via the signals "higher speed" and "lower speed"
load balancing can be executed in island parallel
mode with multiple engines.

Continue with
machine running
phase 4

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Grid failure no longer active via the signal "grid failure from
customer system":
Return synchronization of the grid circuit breaker MCB occurs
in two ways:
Interruption-free
 Variant 1: When the grid failure is resolved, the grid
stabilization time will be started (adjustable timer).
After the grid stabilization time has elapsed and the
signal "enable synchronization (MCB)" (= high) has
been activated, the grid circuit breaker (MCB) will
be synchronized. If within this time another grid
failure occurs, the return synchronization will be
interrupted and grid backup mode will be continued.
After the generator circuit breaker has been
opened, the signal, "enable synchronization (GCB)"
must be set to low.
 Variant 2: The grid circuit breaker MCB can be
return synchronized by the customer system
Machine running controller. To do this, the signals "higher speed"
phase 4 and "lower speed" must be used.
With interruption:
When the grid failure is resolved, the grid stabilization time will
be started (adjustable timer). After the grid stabilization timer
has elapsed, the signal, "enable synchronization (GCB)" (=
low) must be withdrawn. The generator circuit breaker (GCB)
will be opened through this measure.
 Variant 1: With activated signal "enable
synchronization (MCB)" (= high) and "black start
MCB" (= high) the grid circuit breaker MCB will be
closed if the busbar is de-energized.
If the grid circuit breaker MCB is closed, the signal,
"enable synchronization (MCB)" must be set to low.
 Variant 2: The grid circuit breaker MCB can be
closed by the customer system controller.

The generator circuit breaker MCB will now be re-

synchronized with the signal "enable synchronization (MCB)"
(= high).

 If both circuit breakers (GCB + MCB) are closed, at

activated signals ("engine start" (= high) and signal
Grid backup mode
"enable synchronization (GCB)" (= high), grid
backup mode will be continued.
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 Start- / Stop Procedure
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11.5.3 Operating Mode: No Interruption at Grid Failure - Machine is running and a Grid
Disturbance Occurs
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 Signal "engine start" = high

 Signal "enable synchronization (GCB)" = high
 Grid backup enabled via signal "grid backup
operation active" (= high).
 A grid fault is detected by the customer system
Machine running
controller:
phase 0
The grid circuit breaker MCB must be closed by the
customer system controller.
The signal "grid fault from customer system" must
not be activated. Otherwise the generator circuit
breaker GCB will be opened without delay and
interruption-free grid backup mode is not possible.

 Grid backup mode is active if the grid circuit

breaker MCB is open and the generator circuit
breaker (GCB) is closed: Frequency regulation in
Machine running the MIP 4000 is activated.
phase 1
 Via the signals "higher speed" and "lower speed"
load balancing can be executed in island parallel
mode with multiple engines.

Return synchronization of the grid circuit breaker MCB occurs

in two ways:
Interruption-free
 Variant 1: When grid power is restored, the signal
"enable synchronization (MCB)" (=high) is
activated, this synchronizes the grid circuit breaker
(MCB).
If the generator circuit breaker is closed, the signal,
"enable synchronization (MCB)" must be set to low.
 Variant 2: The grid circuit breaker MCB can be
return synchronized by the customer system
controller. To do this, the signals "higher speed"
Machine running
and "lower speed" must be used.
phase 2
With interruption:
At return of grid power the signal "Enable synchronization
(MCB)" (= low) must be withdrawn. The generator circuit
breaker (GCB) will be opened through this measure.
 Variant 1: With activated signal "enable
synchronization (MCB)" (= high) and "black start
MCB" (= high) the grid circuit breaker MCB will be
closed if the busbar is de-energized.
If the generator circuit breaker is closed, the signal,
"enable synchronization (MCB)" must be set to low.
 Variant 2: The grid circuit breaker MCB can be
closed by the customer system controller.

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 Start- / Stop Procedure

The generator circuit breaker MCB will now be re-

synchronized with the signal "enable synchronization (MCB)"
(= high).

 If both circuit breakers (GCB + MCB) are closed, at

activated signals ("engine start" (= high) and signal
Grid parallel mode
"enable synchronization (GCB)" (= high), grid
backup mode will be continued.
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 Software Communication
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12 Software Communication
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12.1 General
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All data (temperatures, alarm messages, status messages, etc.) is available in the interface protocol. The
communication interfaces are set up to bidirectional operation.
 Deviations from the standard protocol (e.g. special commands, setpoint specifications, etc.) must be
clarified as needed. Adaptations will be billed based on time and materials.
 The software in the external system will not be adjusted by MTU Onsite Energy.
 The data length in MIP 4000 interface protocol version 1 is 320 bytes.
 The data length in MIP 4000 interface protocol version 2 is 640 bytes.
 All data is data type "INTEGER (-32768 to + 32767).
For the binary values, the data point is queried for status 0/1 bit by bit:
16 binary values (BOOL) per data point.
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12.2 Data Protocol

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The protocol is divided into several areas:

MIP 4000 interface protocol version 1:
Actual values (status) - 280 bytes (140 words):
 Alarm messages
 Status messages
 Analog values / process values (actual values)
 Control values to the outside
Setpoints (control) - 40 bytes (20 words):
 Control values from the outside
 Setpoints / actual values from the outside
MIP 4000 interface protocol version 2:
Actual values (status) - 600 bytes (300 words):
 Alarm messages
 Status messages
 Analog values / process values (actual values)
 Control values to the outside
Setpoints (control) - 40 bytes (20 words):
 Control values from the outside
 Setpoints / actual values from the outside
The data protocol is provided in a separate Excel list!
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 Software Communication
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12.3 Alarm Messages

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The alarm messages are evaluated via the status 0/1.

If there is a queued alarm message the appropriate bit is set to "1".
Example:
Fault messages 8 and 14 are active:
The data point has the status "00100000 10000000".
Thus the individual fault messages can be easily masked (AND link).
Only MIP 4000 interface protocol version 1:
There are up to 1232 fault messages.
These are transferred in 24 data words.
24 words for the fault messages and 1 word for the multiplexer are necessary to transfer all 1232 alarm messages:

Value -
multiplexer (word Alarm message number (word 1 - 24)
0)
1 1 - 384
2 385 - 768
3 769 - 1152
4 1153 - 1232
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12.4 Status Messages

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The status messages are evaluated via the status 0/1.

If there is a queued status message the appropriate bit is set to "1".
Example:
Status messages 8 and 14 are active:
The data point has the status "00100000 10000000".
Thus the individual status messages can be easily masked (AND link).
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12.5 Scaling of Values

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Most values are provided with a so-called "scaling factor" (e.g. x 10).
Thus it is possible to simulate a real number (floating point) on the opposite station.
Example:

Grid frequency 49.99 Hz

Unit / scaling factor Hz x 100
Data value: 4999

The receiving station reads out the value and must divide it by 100. Then the system can continue to work with a
real number.
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12.6 Error Evaluation - External Communication

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MIP 4000 interface protocol version 1:

To check the function of the interface, in the last status value (word 140), a value is written cyclically that is
expected back on the setpoints in the last word (word 20).
If this does not happen, after approx. 1 second the controller will be deactivated via the interface and a alarm
message will be output.
MIP 4000 interface protocol version 2:
To check the function of the interface, in the last status value (word 300), a value is written cyclically that is
expected back on the setpoints in the last word (word 20).
If this does not happen, after approx. 1 second the controller will be deactivated via the interface and a alarm
message will be output.
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12.7 Ethernet (RJ45) with UDP Protocol - Standard

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With this interface data can be read from an Ethernet UDP station or data can be sent to an Ethernet UDP station.
 As opposed to the other interfaces for Ethernet UDP at the beginning of the send and receive
telegram a header with 2 bytes is added.
 This headed contains the number of the module
(module 1 has the number 1; module 2 has the number 2, etc.)

Designation Standard set value

Baud rate (external): e.g. 100 Mbit/s
Protocol: UDP (User Datagram Protocol) in accordance with RFC 768, Internet
protocol
Transmission mode 1 = receive mode
(viewed from the MMC) 2 = transmit mode
3 = receive and transmit mode
The MIP uses receive and transmit mode.
Cable: CAT 5
Cable 1:1: A switch must be used.
Direct communication with external CPU: A crossed cable must be used.
IP address (B&R CPU): 192.168.10.211.
Additional CPUs have an offset of 1 (e.g. 192.168.10.212).
Port (B&R CPU): 21101
Additional CPUs have an offset of 1 (e.g. 21102).
IP address (receiving station): Must be reachable with the subnet mask 255.255.254.0.
Port (receiving station): Same port as for CPU (21101)
Telegram header: 2 bytes (module number)
Receive data as viewed from the  MIP interface protocol version 1:
MMC: 280 bytes
(data is written from the MIP) + 2 byte header.
 MIP interface protocol version 2:
600 bytes (data is written from the MIP) + 2 byte header.
Transmission data as viewed from 40 bytes
the MMC: (data is written from the MIP) + 2 byte header.
Send/transmit cycle: 50 ms
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12.7.1 Presentation - UDP Protocol

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Receive data as viewed from the MMC:

MIP 4000 interface protocol version 1:
Payload data bytes (282 bytes)

Telegram Fault Status Analog values / Control commands

header messages messages process values to the outside
(2 byte) (50 bytes) (30 bytes) (196 bytes) (4 bytes)

MIP 4000 interface protocol version 2:

Payload data bytes (602 bytes)

Telegram Fault Status Analog values / Control commands

header messages messages process values to the outside
(2 byte) (154 bytes) (30 bytes) (410 bytes) (6 bytes)
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Transmission data as viewed from the MMC:

Payload data bytes (42 bytes)

Telegram Control commands Setpoints

header to the MIP to the MIP
(2 bytes) (4 bytes) (36 bytes)

Data stream:

Low byte High byte Low byte High byte

Binary signal

Low byte High byte

BIT BIT

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
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12.7.2 RFC 768 - Standard: User Datagram Protocol (UDP)

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The User Datagram Protocol (UDP) enables packet-switched communication in a contiguous computer network.
The prerequisite for this protocol is that the Internet protocol (IP) must be used as the underlying protocol. With this
protocol messages from user programs can be sent to other programs; in this process only a minimum protocol is
used.
The protocol works without connection. There is no guarantee that packet, once sent, will also arrive. Applications
that require a reliable provision of data streams should use the transmission control protocol, (TCP).

0 78 15 16 23 24 31
Source port Destination
port
Length Checksum
Data ....

User data header format

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Fields:
The source port indicates the port number of the sending process. This information is
Source port: required so that the receiver can respond to the packet. Because UDP is connectionless, the
source port is optional and can be set to the value "0".
Destination port: The destination port specifies which process the packet should receive.
The length indicates the size of the packet, consisting of the data and the header, in octets.
Length:
The smallest possible value is 8 octets.
The checksum is a 16-bit checksum and is formed via the so-called pseudo header and the
Checksum
data.
The pseudo header is conceptually placed in front of the UDP header and contains the source address, the
destination address and the UDP length. This information provides protection against incorrectly routed packets.
This checksum procedure is the same as used in TCP.

0 78 15 16 23 24 31
Source address
Destination address
Zero Protocol UDP length
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 Configuration and Service Wizard
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13 Configuration and Service Wizard

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No. Description
A MIP-CPU with 2 Ethernet interfaces
B Engine interface
C Customer interface
Customer PC / wizard
 Setting the Ethernet IP address
 Setting MIP values (parameters, time, etc.)
D
 Online values
 Alarm logger
etc.

There are 2 Ethernet interfaces available on the CPU:

 The first interface is provided for communication with the customer system controller.
 The second interface can be used for remote access.
The wizard pages can be called up via the installed VNC server in the MIP CPU.
For this shared use of the first interface via a switch is standard.
On the customer side, a VNC viewer is required on the computer.
=== Ende der Liste für T extmar ke Inhalt ===

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MTU Onsite Energy GmbH
Postfach 10 21 30 • 86011 Augsburg
Dasinger Str. 11 • 86165 Augsburg
Tel.: +49 (0)821 / 7480-0
Fax: +49 (0)821 / 7480-2119
Internet: http://www.mtu-online.com
Europe / Middle East / Africa / Latin America Asia / Australia / Pacific USA / Canada / Mexico
MTU Friedrichshafen GmbH MTU Asia Pte. Ltd. MTU Detroit Diesel, Inc.
88040 Friedrichshafen 1, Benoi Place 13400 Outer Drive West
Germany Singapore 629923, Detroit, Michigan 48239,
Republic of Singapore USA
Phone +49 7541 90 7001 Phone +65 6861 5922 Phone +1 313 592 7000
Fax +49 7541 90 7081 Fax +65 6861 3615 Fax +1 313 592 7788
[email protected] [email protected] [email protected]
www.mtu-online.com www.mtu-online.com www.mtu-online.com

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