Hybrid controllers

Hybrid plants are, by nature, “multiple energy” systems. CRE’s approach uses one controller per source and shares real-time data through CAN for coordinated decisions: load demand, reserve power, inverter status, and breaker states. This creates a unified, plant-level control strategy while keeping each controller focused on its role. It also simplifies expansion: adding a new source is typically adding a new controller “item” and integrating it into the CAN network.

Hybrid power plants often need to switch between grid-parallel and island operation—sometimes automatically. CRE controllers support synchronizing functions (frequency, phase, voltage supervision), breaker management, and smooth transitions. Whether the plant runs with mains paralleling or in standalone mode, the goal is stable delivery and safe operation, including dual operating modes and “blackout” recovery scenarios.

A hybrid controller must do more than start/stop assets—it must manage power flow. The range supports active and reactive power control, power factor objectives, and coordinated load behavior. When conditions require it (mains failure, limited generation, inverter constraints), load shedding can prioritize critical loads. Control methods such as optimized PID control are used to improve dynamic response and stability—helping the system run smart and safe, while reducing fuel usage.

With a BESS, energy storage becomes a controllable lever: reduce genset fuel, absorb renewable fluctuations, and support the plant during events. BAT COMPACT manages battery inverter setpoints for charging and discharging, based on plant conditions (load, reserve, source availability). This supports an efficient battery bank strategy, including maintaining operational limits and improving long-term reliability.

Solar and wind inverters must be controlled to match plant objectives, not just maximum production. HYBRID COMPACT interfaces with inverters (typically via Modbus TCP/RTU depending on the setup) to manage renewable power, limit production when needed, and coordinate with gensets and batteries. This helps maximize renewable energy usage while keeping the plant stable and compliant with grid constraints. In some hybrid designs, a renewable source may require a controlled dump load to maintain stability when production exceeds demand—this is handled at system level through the appropriate control strategy and protections.

Hybrid projects succeed when installation and setup are efficient and when operators can understand the system. CRE controllers provide HMI options (panel versions and i4Gen touchscreen compatibility), plant-level views (including single-line style overviews), event and alarm logs, and connectivity for integration with SCADA or supervisory systems (e.g., Modbus TCP client/server). Remote support capabilities can accelerate troubleshooting and reduce downtime—an important part of long-term service. Integration can include both analog and digital signals, depending on metering and breaker interfaces, and project toolkits may include practical accessories such as communication cables, gateways, or interface modules. Configuration remains easy to maintain thanks to structured menus and commissioning guides; firmware updates and configuration files can be managed via local service interfaces such as USB, depending on the project setup.