Project Background & Client Profile
CopperLeaf Power operates a complex hybrid power setup at the Zulu Nyala site.
The site draws power from three primary sources:
The Utility Grid (Mains)
Two Diesel Generators (a CAT set and a Wuxi set)
A Battery/Inverter Bank (six inverters)
Two automated changeover switches and a network of circuit breakers control which source feeds the site load, as well as when the generators are engaged to charge the inverter bank.
Hagar Control was appointed to engineer and commission the automated changeover logic and provide a clear, reliable live system view for site operators. The control logic runs in CODESYS, paired with a Deep Sea Electronics DSE M840 panel-mounted display featuring a custom UI built specifically for the site’s operating requirements.
Project Requirements
The key operational objectives for the project included:
Automated Mode Handling: Real-time changeover control across all operating states, including no-flow/idle, inverters supplying load, generator feeding load, grid feeding load, and three distinct inverter charging modes.
Dual Generator Flexibility: Support for either generator at any time, accounting for individual voltage pickups across both the CAT (G1) and Wuxi (G2) sets.
True Line-State Sensing: Accurate grid-live sensing upstream of the main breaker, ensuring operators can distinguish between active grid supply and breaker status (“grid live, breaker open”).
Comprehensive Operator Menus: Dedicated screens for operating modes (Stop, Auto, Manual), digital inputs/outputs, equipment parameters, voltage and current metering, and CAN bus diagnostics for the M840 and EM1000 modules.
Hardware Integration: Integrating a custom UI tailored specifically to the physical capabilities and memory constraints of the 4.3-inch DSE M840 display hardware.
The Solution
CODESYS Automation & Custom UI Integration
To handle the complexity of the site, Hagar Control developed a unified control and display model based directly on the physical single-line diagram and real-time PLC inputs.
System Control & Power Flow Logic
The system evaluates all live signals from the PLC—covering 1,152 potential switching combinations—to manage changeover sequences accurately and output live operating status directly to the display:
Grid Priority & Fallback: Smooth transition between utility mains, inverter power, and dual generator backup.
Dynamic Charging Modes: Automatic engagement of generator power to recharge inverters based on battery state and site load.
Fault Handling: Automated fallback strategies to maintain uninterrupted supply during inverter or mains faults.
Custom UI Development
Hagar Control integrated a custom UI designed specifically for the DSE M840 display screen. Instead of generic status indicators, the display features custom-built equipment icons, live menu navigation, and animated power-flow graphics that reflect actual physical current flow
Implementation
Hagar Control’s engineers wired the field signals, programmed the changeover logic in CODESYS, and flashed the screen package to the controller.
| Area | Detail |
| Monitored Signals | Mains live · Mains breaker closed · G1 running · G2 running · Changeover 1 (CO-1) position · Inverters supplying · Breaker 2 (CB2) · Breaker 3 (CB3) · Changeover 2 (CO-2) position |
| Controlled Outputs | Mains breaker, main changeover switch, inverter load breakers, and generator remote start commands |
| Operator Interface | Custom UI on 4.3″ DSE M840 display (Power mimic, Stop/Auto/Manual control, I/O status, Device info, Voltages & Currents, CAN diagnostics) |
During integration, additional operational enhancements requested by CopperLeaf were incorporated, including dedicated G1/G2 status modes, upstream grid indication, and an automated inverter fault fallback routine to ensure uninterrupted power.
Results & Impact
100% Operational Coverage: Complete coverage of all 1,152 signal combinations across grid, dual generator, and inverter operations.
Reliable Live Monitoring: True representation of line conditions and breaker positions prevents false readings during changeover steps.
Optimised Hardware Performance: Custom UI tailored specifically to fit within the memory and performance footprint of the DSE M840.
Streamlined Diagnostics: Dedicated CAN bus monitoring (bus load, error counts, lost messages) simplifies ongoing site maintenance.
On Site Feedback
“By tying the display graphics directly to the single-line diagram logic, the operator interface always reflects true line conditions. The result is a complete CODESYS automation scheme that gives operators total clarity over their hybrid power assets.” — Hein Janse van Rensburg, Hagar Control
Future Plans
Next Steps/Follow-on Projects:
Fault Recovery Upgrades: Future phases will expand the automated fallback logic to seamlessly isolate inverter failures and initiate generator auto-starts when mains is unavailable.
Modular Reusability: The underlying control framework and UI design system can be adapted directly to future hybrid power and generator changeover projects using Deep Sea Electronics hardware.
