guide to load share system design and commissioning

8/13/2019 Guide to Load Share System Design and Commissioning

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057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 1

DEEP SEA ELECTRONICS PLC

Load Share System Design andCommissioning

Using the DSE 55xx range of ProductsIncluding 5xx

Authors: - John RuddockMiles RevellTony Manton


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2 057-047Load Share System Design and Commissioning ISSUE2 25/7/07 AM

Deep Sea Electronics PlcHighfield HouseHunmanbyNorth YorkshireYO14 0PHENGLAND

Sales Tel: +44 (0) 1723 890099Sales Fax: +44 (0) 1723 893303

E-mail: [email protected]

Deep Sea Electronics PlcAll rights reserved. No part of this publication may be reproduced in any material form (includingphotocopying or storing in any medium by electronic means or other) without the writtenpermission.

Any reference to trademarked product names used within this publication is owned by theirrespective companies.

Deep Sea Electronics Plc reserves the right to change the contents of this document without priornotice.

Should you have any queries arising from this manual please contact our Technical Department:

INTERNATIONAL TEL: +44 (0) 1723 890099INTERNATIONAL FAX: +44 (0) 1723 893303

E-mail: suppor [email protected] Web: http: //www.deepseaplc.com


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TABLE OF CONTENTS

Section Page

1 INTRODUCTION .............................................................................................. 42 STEP BY STEP GUIDE.................................................................................... 4

2.1 CLARIFICATION OF NOTATION AND TERMINOLOGY USED WITHIN THISPUBLICATION. ............................................................................................................................... 5

3 BASIC SYSTEM ARRANGEMENT ................................................................. 73.1.1 PRIME POWER ............................................................................................................73.1.2 SINGLE MAINS SUPPLY ..............................................................................................83.1.3 MULTIPLE MAINS SUPPLIES ......................................................................................9

4 CONSIDERATIONS ....................................................................................... 114.1 GOVERNORS ....................................................................................................................12

4.1.1 ANALOGUE OUTPUT CONTROL / P120 CONTROL ................................................124.1.2 CAN CONTROL (5510 / 5520 ONLY) .........................................................................12

4.2 AUTOMATIC VOLTAGE REGULATOR ............................................................................124.3 LOAD SWITCHING DEVICES ...........................................................................................134.3.1 CONTACTORS ...........................................................................................................134.3.2 CHARGED SPRING BREAKERS ...............................................................................134.3.3 AIR CIRCUIT BREAKERS (ACB) ...............................................................................134.3.4 MOTOR OPERATED BREAKERS .............................................................................134.3.5 MANUALLY OPERATED BREAKERS .......................................................................13

5 SETTING UP THE SYSTEM .......................................................................... 155.1 THE BASICS ......................................................................................................................155.2 TAKING CONTROL ...........................................................................................................15

5.2.1 INITIAL SETUP ...........................................................................................................155.2.2 LOAD ACCEPTANCE TEST .......................................................................................165.2.3 FULL LOAD TEST .......................................................................................................165.2.4 QUAD DROOP SET-UP ..............................................................................................165.2.5 INTRODUCING THE DSE ANALOGUE GOVERNOR CONTROL ............................175.2.6 INTRODUCING THE DSE ANALOGUE AVR CONTROL ..........................................21

5.3 TESTING THE CONTROLS ...............................................................................................255.3.1 TESTING ANALOGUE SPEED AND VOLTAGE CONTROL .....................................255.3.2 SYNC CHECKS ..........................................................................................................27

5.4 SYNCHRONISING .............................................................................................................285.5 ADJUSTING RESPONSE ..................................................................................................29

5.5.1 ANALOGUE SCHEME ................................................................................................295.5.2 PULSE SCHEME ........................................................................................................30

5.6 LOAD SHARING ................................................................................................................315.7 ADJUSTING RESPONSE ..................................................................................................31

5.7.1 ANALOGUE SCHEME ................................................................................................315.7.2 PULSE SCHEME ........................................................................................................315.8 PARALLEL WITH MAINS SUPPLY ..................................................................................32

5.8.1 5510 .............................................................................................................................325.8.2 5520 .............................................................................................................................325.8.3 5560 .............................................................................................................................335.8.4 550 / 555 / 557 ............................................................................................................345.8.5 556 ...............................................................................................................................34


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1 INTRODUCTION

Load share systems can be complex and confusing when first approached. The purpose of thisguide is to highlight the steps needed to design the system, specify the components, test andcommission the final solution.

The guide deals with this in two sections; the design stage or thinkingstage and then thetest/commission stage or Doingstage.

By following the stages, you will be able to find which module is most suitable for the application.

The information contained in this manual is intended to be used with reference to the followingDSE documents:-

5000 series controllers 500 series controllers

Guide to Synchronising and Load SharingPART I & II

5xxx configuration software manual 5510 Operators Manual 5520 Operators Manual 5560 Operators Manual Link5000plus Software Manual

Guide to Synchronising and Load SharingPART I & II

P810 Software Manual 550 Operators Manual 555 Operators Manual 556 Operators Manual 557 Operators Manual Link500plus Software Manual

2 STEP BY STEP GUIDE

This section details the main steps that need to be taken in producing your synchronising / loadsharing system. This is intended as a guide only and is not a substitute for in depth knowledge ofsynchronising and load sharing.

Identify your base application . Applications supported by the DSE controllers are

detailed in the section headed Synchronising and load sharing solutions. Identify your governor and AVR interface methods . Details of this are contained

in the Guide to Synchronising and Load Sharing Part2, under the headings Interfacing togovernorsand interfacing to Automatic voltage regulators.

Design your panel and system wiring. DSE can assist with your specific questionson this but cannot design your panel for you. If you want a panel designing, please contactDSE Technical Support Department who may be able to recommend a third party paneldesigner / builder capable of producing a synchronising / load sharing system.

Check / adjust the DSE modules configurationusing the configuration software.If it is a Multiset system, ensure that the settings for Multiset Comms Link are correctlyconfigured and the Multiset comms cable is of the correct specification.

Commission each set in the system as a single standalone set.Before doing

this, ensure the governor/AVR interface is disabled as detailed in the section entitled On sitecommissioning.

Set up the governor and AVRas detailed in their respective manufacturershandbooks.

Before synchronising setsfor the first time, double checkthat all the Bus wiring iscorrect and that the controllers initial settings are suitable. This may include lowering thesettings for gain and stability in the synchronising, voltage matching and load controlsections. Details of ways to verify these are included in the section entitled Controllercommissioning adjustments.

Should you have any queries arising from this manual please contact our Technical Department:

INTERNATIONAL TEL: +44 (0) 1723 890099INTERNATIONAL FAX: +44 (0) 1723 893303

E-mail: suppor [email protected] Web: http: //www.deepseaplc.com


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2.1 CLARIFICATION OF NOTATION AND TERMINOLOGY USED WITHINTHIS PUBLICATION.

NOTE: Highlights an essential element of a procedure to ensurecorrectness.CAUTION Indicates a procedure or practice which, if not strictly observed,could result in damage or destruction of equipment.WARNING Indicates a procedure or practice, which could result in injury topersonnel or loss of life if not followed correctly.

DEEP SEA ELECTRONICS PLC own the copyright to this manual,which cannot be copied, reproduced or disclosed to a third partywithout prior written permission.Compliant with BS EN 60950 Low Voltage DirectiveCompliant with BS EN 50081-2 EMC DirectiveCompliant with BS EN 50082-2 EMC Directive

Year 2000 Compliant

Two crossing wires with no interconnection between the two.

Three wires, all connected together

Connections to the 55x controllers battery supply negative terminal,usually the earthed battery ve terminal.

A.V.R.Automatic Voltage Regulator. Fitted to the alternator to regulate theoutput of the generator.

GovernorEngine Speed Governor. Fitted to the engine to electronically control

the speed of the engine.

Droop

When load is applied to a generator fitted with a droop governor /AVR, the speed/voltage will drop. This is called droop. It is commonfor a droop set to drop between 3% and 10% in speed / voltage fromno load applied to full load applied.

IsochronousA governor with no speed droop, or where speed droop is disabled isknown as an isochronous governor. The engine speed remainsconstant so long as the load levels are within the sets capability.

Synchronise To get the supplies identically matched, ready for paralleling.

ParallelConnect two or more supplies together. These supplies must be insynchronism before this can occur.

Datumcentre point of an electronic pot, digital resistance orAVR/Governor.

Nominal

The nominal voltage or frequency of the system i.e. 230V 50Hz. Thisis not necessarily the same as the Datum.(i.e. when droop governors/AVRs are used, the datum will be higherthan the nominal )

Mains supplyThe AC distributed power supply of a power generation company.Often also called the grid, or utility supply.


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3 BASIC SYSTEM ARRANGEMENT

The first consideration is the basic layout of the main components in the system.The following pages show typical applications, and what is needed to meet the systemrequirements.

This list is not exhaustive; please call us if you have requirements not detailed in the followingsections.

3.1.1 PRIME POWER

SINGLE SET

Although not requiring a sync/load share controller, this has been included for completeness.A single generating set is used to provide power to theload.The set can be either manually or remotely controlled.

MULTIPLE SET

The generators are controlled by 5510 or 550 controllers.Two or more sets are used to provide power to the load,sharing power equally as a percentage of the sets fullload rating. Sets are automatically started and stoppeddepending upon load levels allowing economic use ofthe available generators.


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3.1.2 SINGLE MAINS SUPPLY

NOTE: - It is recommended that ROCOF (Rate of change of frequency) or vector shiftdetection components are fitted when paralleling a generating set with the mains supply.Additional equipment of this type is normally specified by the local electricity SupplyCompany. This protects against the generator feeding the mains grid in the case of amains failure. However, in applications of this type, where parallel time is kept to aminimum, this is usually not a requirement.If in doubt, you should refer to your local Electricity Supply Company for advice.

SINGLE GENERATOR

In this system, a single 5520, 557 or 555 controller is used to control the generator and loadswitching system, providing integral mains monitoring.

A single generating set is used to provide backup to the

mains supply.When the mains supply fails, the set is started, andclosed onto the load.

When the mains supply returns, there will be NObreakin supply to the load while a ramped transfer takesplace.This system can also be configured to start the set upon rising load levels to allow the set to beused for peak lopping (5520 controller only).

MULTIPLE GENERATORS

In this system, 5510 or 550 controllers are used to control the generators.Mains monitoring and mains transfer switching is provided by the 5560 or 556 controller.

Multiple generating sets are used to provide backup tothe mains supply.When the mains supply fails, the sets are started,paralleled and closed onto the load.

Sets can also be configured to start and stopautomatically upon rising/falling load levels.

When the mains supply returns, there will be NObreakin supply to the load while a ramped transfer takesplace.This system can also be configured to start the set upon rising load levels to allow the sets to beused for peak lopping.


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3.1.3 MULTIPLE MAINS SUPPLIES

NOTE: - It is recommended that ROCOF (Rate of change of frequency) or vector shiftdetection components are fitted when paralleling a generating set with the mains supply.Additional equipment of this type is normally specified by the local electricity SupplyCompany. This protects against the generator feeding the mains grid in the case of amains failure. However, in applications of this type, where parallel time is kept to aminimum, this is usually not a requirement.If in doubt, you should refer to your local Electricity Supply Company for advice.

SINGLE GENERATOR

In this system, the generator is controlled by 5510 or 550 load share controller.The mains controllers/ATS are 5560 controllers.

A single 5510 controlled generating set is used toprovide backup to multiple mains supplies, controlled

with 5560 modules.When a mains supply fails, the set is started, and closedonto the generator bus.The generator bus is then closed to feed the load.

Should more than one mains supply fail, theirappropriate loads are also transferred to the genset.

When a mains supply returns, there will be NObreak insupply to the load while a ramped transfer takes place.

If all mains supplies return together then the mainspriority is used to determine which mains transfer first,each mains supply is paralleled with the genset and theappropriate load is ramped onto the mains supply, untilall mains supplies are back on load.


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MUTLIPLE GENERATORS

In this system, the generators are controlled by 5510 controllers.The mains controllers/ATS are 5560 controllers.Two or more sets controlled by 5510 modules, are usedto provide backup to multiple mains supplies, controlled

with 5560 modules.When a mains supply fails, the sets are started,synchronised and paralleled together. The generatorbus is then closed to feed the load, the sets sharingpower equally as a percentage of their full load rating.Sets are automatically started and stopped dependingupon load levels allowing economic use of the availablegenerators.

Should more than one mains supply fail, theirappropriate loads are also transferred to the gensets.

When a mains supply returns, there will be NObreak in

supply to the load while a ramped transfer takes place.

If all mains supplies return together then the mainspriority is used to determine which mains transfer first,each mains supply is paralleled with the gensets andthe appropriate load is ramped onto the mains supply,until all mains supplies are back on load.


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4 CONSIDERATIONS

Having studied the basic layouts shown previously and found the one closest to your applicationyou need to ask the following questions. Use this list as a checklist and tick the boxes once eachitem has been appraised:

What is the wiring topography of the system (i.e. 3 phase 4wire star)?

What is the nominal voltage?

Where are the breakers in relation to the bus?

Where are the breakers in relation to the load?

Are the breakers in the same location as shown in the preceding drawings?

Is there a mains supply involved?Is more than one mains supply involved?

Are there any bus couplers in the system?

If replacing an existing control scheme what is the current start-up andshutdown procedure?

Are there any special operating conditions to take into account?

What is the electronic governor type?What is the AVR type?The answers to the above questions can affect how the application will need to be tackled. Forassistance, please contact DSE technical support staff.


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4.1 GOVERNORS

DSE 55xx modules interface to the electronic governor on the engine using either theanalogue governor output or the CAN interface (when used in conjunction with a suitableelectronic engine).

The DSE 55x module interfaces to the electronic governor on the engine using the P120

interface.

4.1.1 ANALOGUE OUTPUT CONTROL / P120 CONTROL

The 5000 series analogue governor output or the 500 series P120 interface is used to control theengine speed via the governor speed bias input.The governor input needs to accept the 0-10V DC signal used. DSE has detailed the connection tomany governor systems commonly found in the industry please refer to The guide toSynchronising and load share PART 2 for further details.

4.1.2 CAN CONTROL (5510 / 5520 ONLY)

5510/5520 controllers have integral CAN interface to communicate with compatible engine ECUs.Some (but not all) CAN enabled engines are capable of receiving speed control signals from theDSE CAN controller for synchronising and load sharing purposes. This replaces the requirement toconnect the analogue governor output A/B connections to the speed governor.At the time of writing compatible engines with speed control via CAN are MTU MDEC V3.04,Scania S6, Volvo EMS2.For connection and setup details please refer to The guide toSynchronising and load share PART 2.

4.2 AUTOMATIC VOLTAGE REGULATOR

DSE 55xx modules interface to the AVR on the alternator using either the analogue AVRoutput.

The DSE 55x module interfaces to the electronic governor on the engine using the P121

interface.

The 5000 series analogue AVR output or the 500 series P121 interface is used to control theengine speed via the governor speed bias input.The AVR input needs to accept the 0-10V DC signal used. DSE has detailed the connection tomany AVR systems commonly found in the industry please refer to The guide to Synchronisingand load share PART 2 for further details.

It is recommended that the AVR be fitted with a quad droop kit to give correct operation when inparallel. For further details, you are referred to your alternator / AVR supplier.


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4.3 LOAD SWITCHING DEVICES

It is typically considered that load switching for parallel supplies be performed within 5 cycles of theclose signal being given to ensure the phase or the supplies has not changed too greatly after theclosing signal has been given. For instance a change of load will affect the phase.

Cycle time Max load switchclosing time

50Hz system 20.0 ms 100 ms

60Hz system 16.7 ms 83 ms

NOTE: - The closing time of any load switching device slave relays should also betaken into account. For instance, plug in relays typically used in generating set controlpanels have an operation time of 10-20mS.4.3.1 CONTACTORS

Contactors normally operate fast enough for paralleling applications but care should be taken to

choose a contactor that the manufacturer specifies be fast enough for use in parallelingapplications. (See above).

4.3.2 CHARGED SPRING BREAKERS

In general, charged spring breakers will operate much faster than contactors.Charged spring breakers pre charge a large spring device within the breaker, so that whenbreaker operation is required, the spring is released which operates the closing action of thedevice.Typically, the spring is charged when the undervolts input is energised, normally when the set isfirst started. Once charged, the breaker is ready for the closing signal.

4.3.3 AIR CIRCUIT BREAKERS (ACB)

A.C.B.s normally operate fast enough for paralleling applications but care should be taken tochoose an A.C.B. that the manufacturer specifies be fast enough for use in paralleling applications.(See above).

4.3.4 MOTOR OPERATED BREAKERS

Some types of motor operated breakers are not suitable for paralleling operations due to theexcessive amount of time that the breaker takes to motor into position before the closing processcan be completed. Care should be taken to choose a motor operated breaker that themanufacturer specifies be fast enough for use in paralleling applications. (See above).

4.3.5 MANUALLY OPERATED BREAKERS

Manually operated breakers cannot be closed in the time required of a synchronising system andmust notbe used.


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5 SETTING UP THE SYSTEM

Once all aspects of the design have been considered and the system has been designed, it isready for setting up, testing and commissioning.

5.1 THE BASICS

It will notbe possible to commission a load sharing system unless the basicsare correct to beginwith.

The setup of the module is covered in the relevant manuals and is outside the scope of thisdocument. However, before proceeding the following should be checked. Use this section as achecklist and tick the boxes when each item has been appraised.

System drawings to ensure correct connection of the module and othercomponents

Module configuration to ensure correct settings in the unit for the applicationAFTER these have been confi rmed, the next stages are:-

Connect the system upConfigure the moduleCheck to ensure correct settings on the MSC (Multi Set Comms) Link.

NOTE:-DO NOT CONNECT the Governor or AVR interface (or P120 / P121) to thegovernor and AVR at this time.5.2 TAKING CONTROL

5.2.1 INITIAL SETUP

The first stage of testing is to set up the governor correctly and then to allow the DSE module totake control over it.

Start the engine and follow the governor manufacturers recommended start up procedure. This willresult in the engine running at the correct speed (i.e. 50Hz). Following the manufacturersrecommendations set the GAIN and other settings to ensure stable running.

Set up the AVR to give the correct output volts (i.e. 230V) and following the manufacturersrecommendations to set the gain and other settings to ensure stable output.


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5.2.2 LOAD ACCEPTANCE TEST

Apply approximately 50% (or manufacturers recommendation for percentage load acceptancetests) load to the generating set and check that the response is acceptable.The engine should accept load and return to stable running at the set value (i.e. 50Hz/230V).

Check that the DSE module is reading the correct kW and PF. If these are wrong, check that theconnections to the CTs and that the CTs are the right way round.

NOTE:- Occasionally CTs are manufactured incorrectly - The terminal designationsare reversed ie S1/S2 or P1/P2 are transposedRemove the load and check that the response is acceptable. The engine should drop the load andreturn to stable running at the set value (i.e. 50Hz/230V).

If the load acceptance tests show instability or reluctance to accept load, adjust the governor(speed) and AVR (Volts) GAIN and STABILITY settings and repeat unit the correct response isachieved.

Some governors and AVRs also have a DERIVATIVE setting that can be adjusted. Refer to themanufacturer instructions for more detail.

5.2.3 FULL LOAD TEST

Once load acceptance is verified, apply full load to the set. Ensure full load is achieved. If not,check the governor and actuator settings as these may limit the amount of load the system willtake. If changes are required, repeat above set-up procedure.

5.2.4 QUAD DROOP SET-UPWhen the governor is setup satisfactorily, the quadrature droop on the AVR must be set upcorrectly. 5% droop on full reactive load is typical a reactive load bank is needed for this test.

Again, if any changes are required repeat the setup above to ensure correct response.


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5.2.5 INTRODUCING THE DSE ANALOGUE GOVERNOR CONTROL

5510 / 5520 controller

The software selectors SW1 and SW2 should have been set to the correct values for thegovernor being used. These are located with the recal section of the 5xxx configuration

software. SW1 sets the centre or off-set speed, and SW2 sets the amount of swing inspeed allowed (gain).

Connect the analogue governor output A/B terminals to the engine governor speed controlor sync/load share terminals as required.

Full connection details and suggested switch setting for many common governor systems can befound in The guide to sync and load sharing PART 2.

550/555/556 controller

The two rotary switches on the P120 should have been set to the correct values for thegovernor being used. SW1 sets the centre or off-set speed, and SW2 sets the amount ofswing in speed allowed (gain). Connect the P120 governor interface A/B terminals to the

engine governor speed control or sync/load share terminals as required. DO NOT connect the P120 to the DSE contro ller at th is t ime.

Full connection details and suggested switch setting for many common governor systems can befound in The guide to sync and load sharing PART 2.


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SETTING SW1 (CENTRE)

SW1 sets the centrepoint of the analogue governor output (or P120).

5510/5520 controller

The generator should be kept running but off load (breaker / contactor open).

After connection of the analoguegovernor output, the engine speed mayhave changed.Using 5xxx configuration software, goto the Re-calibrate | Sync + load control| Governor/AVRinterface tab as shownopposite.SW1 should be adjusted until theengine speed is as close as possible tothe desired speed.Then trim the engine speed to the

exact value (if required) using thespeed trim potentiometer on the enginegovernor.

Once the speed has been set,increasing SW1 will increase ordecrease the speed.If the speed increased when SW1 isturned clockwise, then the Governor

output reversed tick box on the EditConfig | Generator | Sync / load control| Auto synctab of 5xxx configurationsoftware should be left un-ticked.

If however the speed had decreasedwhen SW1 was increased, then theGovernor output reversed tick boxshould be ticked.

NOTE: - If the generator speed remains unchanged when SW1 is adjusted, the DSEmodule has no control over the governor. Carefully check the governor settings andconnections, if in doubt consult the engine manufacturer.

NOTE: - If the wiring between the governor and the DSE module is the wrong wayround, it could give the appearance of a governor that requires the Governor outputreversed field to be ticked. Therefore, care should be taken to make sure that the wiringis correct.


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The P120 governor interface should be disconnected from the 55x controller, but connected to thegovernor.

The speed of the generator may have changed. SW1 on the P120 should be adjusted until theengine speed is as close as possible to the desired speed. E.g., the desired speed may be 50Hzbut changing SW1 one notch may alter the speed from 49.8Hz to 50.2Hz. This means that oneposition of the switch changes the engine speed by 0.4Hz. Once SW1 has been adjusted to set thespeed as close as possible to the desired speed, the speed trim potentiometer on the governorshould be adjusted to tune the engine speed.

Once the speed has been set,adjusting SW1 on the P120 interfaceone position clockwise will increase ordecrease the speed. Using the aboveexample, the speed changes by 0.4 Hz

for every position SW1 changes. If thespeed had increased when SW1 wasturned clockwise, then the Governoroutput reversed tick box on the Editconfig | Generator | Sync / load control| Auto synctab of the P810 softwareshould be left un-ticked.

If however the speed had decreasedwhen SW1 was turned clockwise, thenthe Governor output reversed tick boxshould be ticked.

NOTE:- If the generator speed remains unchanged when SW1 is adjusted, the P120has no control over the governor. Carefully check the governor settings and connections,if in doubt consult the engine manufacturer.

NOTE:- If the wiring between the governor and the P120 interface is the wrong wayround it could give the appearance of a governor that requires the Governor outputreversed field to be ticked. So care should be taken to make sure that the wiring iscorrect.


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SETTING SW2 (RANGE)

SW2 will set how much rangethe analogue governor output (or P120 output) has around thecentre point (centre point was previously set using SW1).

To determine the correct position for SW2, we must first perform a test using SW1:

Adjust SW1 to raise the output frequency by 2.5Hz and note how many positions SW1must be changed.

Use this amount to set SW2 and set SW1 back to its original position.

For example:The generator is running at 50Hz. SW1 is increased by 6 positions until the generator output is52.5Hz.SW1 is reduced by 6 positions (back to its original position) and SW2 is set to 6.

NOTE: - Obviously, the amount of speed range is also dependant on the limits of theGovernor. Typically, a speed range of 2.5 to 3 Hz is required, therefore in this example setSW2 to 6.

NOTE:- 5510/5520 use software settings for SW1 and SW2 with settings possible of0.0-10.0 in steps of 0.1550/555/556 use P120 interface module SW1 and SW2 with settings of 0 -9 in steps of 1.


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5.2.6 INTRODUCING THE DSE ANALOGUE AVR CONTROL

5510 / 5520 controller

The software selectors SW1 and SW2 should have been set to the correct values for theAVR being used. These are located with the re-calibrate section of the 5xxx configuration

software. SW1 sets the centre or off-set voltage, and SW2 sets the amount of range involtage allowed (gain).

Connect the analogue AVR output A/B terminals to the AVR voltage control or sync/loadshare terminals as required.

Full connection details and suggested switch setting for many common AVR systems can be foundin The guide to sync and load sharing PART 2.


The two rotary switches on the P121 should have been set to the correct values for thegovernor being used. SW1 sets the centre or off-set voltage, and SW2 sets the amount ofrange in voltage allowed (gain). Connect the P121 governor interface A/B terminals to the

AVR voltage control or sync/load share terminals as required. DO NOT connect the P121 to the DSE contro ller at th is t ime.

Full connection details and suggested switch setting for many common AVR systems can be foundin The guide to sync and load sharing PART 2.


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SETTING SW1 (CENTRE)

SW1 sets the centrepoint of the analogue AVR output (or P121).

5510/5520 controller


After connection of the analogue AVRoutput, the generator voltage may havechanged.Using 5xxx configuration software, goto the Re-calibrate | Sync + load control| Governor/AVRinterface tab as shownopposite.SW1 should be adjusted until thegenerator output is as close as possibleto the desired voltage.Then trim the voltage to the exact value

(if required) using the speed trimpotentiometer on the AVR.

Once the voltage has been set,increasing SW1 will increase ordecrease it.If the voltage increases when SW1 isturned clockwise, then the AVR output

reversed tick box on the Edit Config |Generator | Sync / load control | Autosynctab of 5xxx configuration softwareshould be left un-ticked.

If however the voltage had decreaseswhen SW1 was increased, then theAVR output reversed tick box shouldbe ticked.

NOTE: - If the generator voltage remains unchanged when SW1 is adjusted, the DSEmodule has no control over the AVR. Carefully check the AVR settings and connections, ifin doubt consult the AVR manufacturer.

NOTE: - If the wiring between the AVR and the DSE module is the wrong way round, itcould give the appearance of an AVR that requires the AVR output reversed field to beticked. Therefore, care should be taken to make sure that the wiring is correct.


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The P121 governor interface should be disconnected from the 55x controller, but connected to theAVR.

The voltage of the generator may have changed. SW1 on the P121 should be adjusted until thegenerator output is as close as possible to the desired voltage.Once SW1 has been adjusted to set the output as close as possible to the desired voltage, the trimpotentiometer on the AVR should be adjusted to tune the alternator output.

Once the voltage has been set,adjusting SW1 on the P121 interfaceone position clockwise will increase ordecrease the output.If the voltage increases when SW1 isturned clockwise, then the AVR outputreversed tick box on the Edit config |

Generator | Sync / load control | Autosynctab of the P810 software shouldbe left un-ticked.

If however the voltage decreases whenSW1 is turned clockwise, then theAVR output reversed tick box shouldbe ticked.

NOTE: - If the generator voltage remains unchanged when SW1 is adjusted, the DSEmodule has no control over the AVR. Carefully check the AVR settings and connections, ifin doubt consult the AVR manufacturer.

NOTE: - If the wiring between the AVR and the DSE module is the wrong way round, itcould give the appearance of an AVR that requires the AVR output reversed field to beticked. Therefore, care should be taken to make sure that the wiring is correct.


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SETTING SW2 (RANGE)

SW2 will set how much rangethe analogue AVR output (or P121 output) has around the centrepoint (centre point was previously set using SW1).

To determine the correct position for SW2, we must first perform a test using SW1:

Adjust SW1 to raise the output voltage by 35V (230V system)and note how manypositions SW1 must be changed.

Use this amount to set SW2 and set SW1 back to its original position.

For example:The generator is running at 230V. SW1 is increased by 3 positions until the generator output is265V.SW1 is reduced by 3 positions (back to its original position) and SW2 is set to 3.

NOTE: - Obviously, the amount of voltage range is also dependant on the limits of theAVR. Typically, a voltage range of 30V-35V (230V nominal system) is required, therefore inthis example set SW2 to 3.

NOTE:- 5510/5520 use software settings for SW1 and SW2 with settings possible of0.0-10.0 in steps of 0.1550/555/556 use P120 interface module SW1 and SW2 with settings of 0 -9 in steps of 1.


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5.3 TESTING THE CONTROLS

Once full control of each generators speed and voltage output has been achieved, each generatoron the common bus should be tested individually, and separately.

550/555/557 only- You can now connect the P120 and P121 interfaces to the 55x controller.

5.3.1 TESTING ANALOGUE SPEED AND VOLTAGE CONTROL

Set the Synchronising reset options, On loadon the Edit config | Generator | Sync / loadcontrol | Auto synctab of the configurationsoftware to Reset to nominal.Set the nominal voltage and nominal frequencyon the Generator volts alarmsand Generatorfrequency alarmstabs of the configurationsoftware to the desired voltage and frequency.For example 230V and 50Hz.


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Ensure that the common bus is dead. Start one of the generators in manual and close the loadswitch device.

5510 / 5520 modules - The breaker/contactor can be closed either by using the transfer to genfascia button, activating an input configured to Transfer to genor by using the SCADA tab on the

PC configuration software. The load switch should close on to a dead bus, and stay closed.

550 / 555 / 557 modules - The breaker/contactor can be closed either by activating an inputconfigured to Transfer to genor by using the SCADA tab on the PC configuration software. Theload switch should close on to a dead bus, and stay closed.

Select the synch scope on the DSE module and check that the phase indicator is in the middle.There should also be a tick next to the Hz and V readings. Both these readings should also bezero.

Stop the generator.

Using the PC configuration software:

Set the nominal voltage on Generator volts alarmstab to 220 V i.e. 10 Volts lower.

Set the nominal frequency on Generator frequency alarmstab to 51 Hz i.e. 1 Hz higher.

Start the generator and close onto a dead bus. Once the switching device is closed, the Volts

should slowly fall to 220 V and the frequency should slowly rise to 51 Hz.

The generator should remain stable at these values. Open the switching device and stop thegenerator, reset the nominal voltage and frequency back to the desired values using theconfiguration software.

This has proven that the DSE module has control over the engine speed and generator voltage.

NOTE: - Repeat the tests for each generator on the system, one at a time.


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5.3.2 SYNC CHECKS

WARNING : Sync checks should only be carried out after all the above tests have beencompleted satisfactorily.

WARNING : Sync checks MUST be carried out on each breaker before it is closed forthe first time onto a live circuit.As a useful commissioning aid, configure one of the LEDs on all of the DSE modules on thecommon bus to Check sync.

On a multi set system, start one of the generators, and close onto a dead bus. Its Check syncLED should illuminate, or if the module is a 5520/555/557 (single set parallel with mains) ensurethe bus is live by closing the mains load switch.

On the module to be tested, disable the breaker/contactor closure circuit, by, for example,removing the control fuse or removing the control relay.

Start the generator in manual and select the Synchroscope displayon the module. Thesynchroscope will indicate the difference in Voltage, frequency and phase angle as follows.

Zero phase angle windowSlowly moving bar to indicate phase angle

Using a fast reacting volt-meter, or light bulb, check that there is a near zeropotential differenceacross the incoming and outgoing terminals of the same phase, of the generator switching device,every time the Check sync LED illuminates. Repeat for all phases.

For the LED configured to Check sync to operate, the following conditions must be met :

The moving phase angle indicator moves through the zero phase angle window

There is a against the frequency and voltage difference displays

WARNING : This test must be done at the switching device terminals, to check forwiring errors. NOT at the back of the DSE module, or intermediate terminals

NOTE: - Repeat the tests for each generator on the system, one at a time.

CAUTION :- These tests must be carried out on every generator on the system.Af ter the above tests have been completed satisfactorily, stop the generator and re-enable thebreaker/contactor closure circuit.


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5.4 SYNCHRONISING

Ensure that the input monitoring the Generator closed auxiliary is set to Electrical trip.

Ensure that the bus is live, either by closing the mains load switch (parallel with mains system) orby starting a generator and closing onto a dead bus (Multiset system).

On the generator to be tested, the sync scope should indicate that the bus is live.


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Start the generator in manual mode.

Once the generator has reached stable conditions, close the load switch.

5510 / 5520 modules - The breaker/contactor can be closed either by using the transfer to genfascia button, activating an input configured to Transfer to genor by using the SCADA tab on the

PC configuration software. The load switch should close on to a dead bus, and stay closed.

550 / 555 / 557 modules - The breaker/contactor can be closed either by activating an inputconfigured to Transfer to genor by using the SCADA tab on the PC configuration software. Theload switch should close on to a dead bus, and stay closed.

5.5 ADJUSTING RESPONSE

5.5.1 ANALOGUE SCHEME

The Analogue scheme is used when the governor / AVR is controlled directly from the analogueoutputs (or P120/P121) of the DSE controller.

As the DSE controller synchronises thegenerator, the response of the generator isadjusted by increasing or decreasing theStability settings on theRe-calibrate | Sync +load control | Synchroniser / volts matchtabof the configuration software. There are twostability settings, one setting for the governorand one setting for the AVR.

The target speed is set via the Slipfrequency, and should be set within thecheck sync window found on the Edit Config |

Generator | Sync / Load control | Check synctab of the configuration software.

NOTE:- Changes to this page are written to the unit automatically. Do not use the writebutton on the onfig Managertab.


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5.5.2 PULSE SCHEME

The pulse scheme is used when thegovernor / AVR are controlled by raise/lowerrelay outputs from the DSE controller.

As the DSE controller synchronises thegenerator, the response of the generator isadjusted using the Response and Stabilitysliders, one set for the governor and theother set for the AVR. The response is howmany pulses there are per second and thestability is the length of the pulse. However ifthe difference between the target and actualis very small, the pulse rate is automaticallyreduced.


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5.6 LOAD SHARING

Load sharing is always automatic and will not be influenced by the speed setting of the governor orthe voltage setting of the AVR. The system will maintain the nominal voltage and nominalfrequency set on theEdit config | Generator | Generator volts alarmsand Generator frequencyalarms tabs of P810 software.

5.7 ADJUSTING RESPONSE

5.7.1 ANALOGUE SCHEME

The Analogue scheme is used when the governor / AVR is controlled directly from the analogueoutputs (or P120/P121) of the DSE controller.

The response of the generator whilst loadsharing is adjusted using the GainandStabilitysliders on theRe-calibrate | Sync+ load control | Load Controltab of theconfiguration software.

There are two gain and stability settings,one for the governor and one for the AVR.

Each time the settings are adjusted the loadmust be changed to test the new settingsand to make sure that the system has notbecome unstable.

NOTE:- Changes to this page are written to the unit automatically. Do not use the writebutton on the onfig Managertab.5.7.2 PULSE SCHEME

The pulse scheme is used when thegovernor / AVR are controlled by raise/lowerrelay outputs from the DSE controller.

The response of the generator whilst loadsharing is adjusted using the Response andStability sliders, one set for the governorand the other set for the AVR. The response

is how many pulses there are per secondand the stability is the length of the pulse.However if the difference between the targetand actual is very small, the pulse rate isautomatically reduced.

NOTE:- Changes to this page are written to the unit automatically. Do not use the writebutton on the Config Manager tab.


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5.8 PARALLEL WITH MAINS SUPPLY

The 5510, 5520, 5560, 550, 555, 556 and the 557 are all capable of running in parallel with themains.

Once the generator has synchronised and closed the generator switching device the function of theDSE controller is varied by both controller type and configuration. The following sections detail thepossibilities:

5.8.1 5510

The controller will instruct the generator toproduct a fixed amount of power.

The generator will maintain the kW andpower factor output that is set on the Re-calibrate, Sync + load control, LoadLevels tab of the 5xxx configurationsoftware.

If the load is less than this output, theremainder will be exported to the mains.Similarly, if the load is greater than thegenerator output, the mains will supplythe remainder.

5.8.2 5520

This controller will operate in one of two modes:

BUS MODE

The generator will maintain the kW and

power factor output that is set on the Re-calibrate, Sync + load control, LoadLevels tab of the 5xxx configurationsoftware.

If the load is less than this output, theremainder will be exported to the mains.Similarly, if the load is greater than thegenerator output, the mains will supply theremainder.

MAINS MODE

The DSE module will control thegenerator(s) to maintain the mains supply

at the kW and power factor output that isset on the Re-calibrate, Sync + load control, Load Levels tab of the 5xxx configuration software.This level can be a mains importor exportlevel.

If the load levels are such that the generators reach 100% of their rating, and the mains supply isnot being held to the levels set, the DSE controller will activate the Insufficient capacity alarm andthe mains will supply the remainder of the load.

NOTE:- When in mains mode, the generators will NEVER be instructed to produce aleading power factor or to produce more than 100%NOTE:- Changes to this page are written to the unit automatically. Do not use the write

button on the Config Manager tab.


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5.8.3 5560


BUS MODE

The generator will maintain the kW and

power factor output that is set on the Re-calibrate, Sync + load control, LoadLevels tab of the 5xxx configurationsoftware.


MAINS MODE

The DSE module will control thegenerator(s) to maintain the mains supplyat the kW and power factor output that isset on the Re-calibrate, Sync + load control, Load Levels tab of the 5xxx configuration software.This level can be a mains importor exportlevel.


NOTE: - When in mains mode, the generators will NEVER be instructed to produce aleading power factor or to produce more than 100%NOTE: - Changes to this page are written to the unit automatically. Do not use the

write button on the Config Manager tab.MULTIPLE MAINS SUPPLIES

The 5560 has support for multiple mains supplies.These supplies are controlled by multiple 5560 controllers. The generator(s) can only be inparallel with one mains supply at a time. Therefore, a priority system exists on the 5560 controllerto determine the order in which the 5560s in the system will take control over the generator set(s).

For further details regarding the use of multiple mains supplies, you are referred to the followingDSE documentation:

Guide to Synchronising and load sharing part 1 5560 operators manual

5xxx configuration software manual

NOTE: - All 5560s in a multi-mains system must be version 6 or above.


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5.8.4 550 / 555 / 557

These controllers will instruct thegenerator to product a fixed amount ofpower.

The generator will maintain the kW andpower factor output that is set on the Re-calibrate, Sync + load control, LoadLevels tab of the P810 configurationsoftware.


NOTE: - Changes to this page are written to the unit automatically. Do not use thewrite button on the Config Managertab.

5.8.5 556


Bus mode

The generator will maintain the kW andpower factor output that is set on the

Re-calibrate, Sync + load control,Load Levels tab of the P810configuration software.

If the load is less than this output, theremainder will be exported to the mains.Similarly, if the load is greater than thegenerator output, the mains will supplythe remainder.

MAINS MODE

The DSE module will control thegenerator(s) to maintain the mains

supply at the kW and power factor output that is set on the Re-calibrate, Sync + load control,Load Levels tab of the P810 configuration software. This level can be a mains importor exportlevel.


NOTE: - When in mains mode, the generators will NEVER be instructed to produce aleading power factor or to produce more than 100%

NOTE: - Changes to this page are written to the unit automatically. Do not use thewrite button on the Config Managertab.


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guide to load share system design and commissioning

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