DEEP SEA ELECTRONICS PLC

Load Share System Design and Commissioning Using the DSE 55xx range of Products
Including 5xx

Authors: -

John Ruddock Miles Revell Tony Manton

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Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303 E-mail: Sales@Deepseaplc.com

Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission. Any reference to trademarked product names used within this publication is owned by their respective companies. Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice.

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

INTERNATIONAL TEL: +44 (0) 1723 890099 INTERNATIONAL FAX: +44 (0) 1723 893303 E-mail: support@deepseaplc.com Web: http://www.deepseaplc.com

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TABLE OF CONTENTS Section

1 2

Page

INTRODUCTION .............................................................................................. 4 STEP BY STEP GUIDE.................................................................................... 4

2.1 CLARIFICATION OF NOTATION AND TERMINOLOGY USED WITHIN THIS PUBLICATION. ...............................................................................................................................5

BASIC SYSTEM ARRANGEMENT ................................................................. 7

3.1.1 3.1.2 3.1.3 PRIME POWER ............................................................................................................7 SINGLE MAINS SUPPLY..............................................................................................8 MULTIPLE MAINS SUPPLIES ......................................................................................9

CONSIDERATIONS ....................................................................................... 11
4.1 GOVERNORS ....................................................................................................................12 4.1.1 ANALOGUE OUTPUT CONTROL / P120 CONTROL ................................................12 4.1.2 CAN CONTROL (5510 / 5520 ONLY) .........................................................................12 4.2 AUTOMATIC VOLTAGE REGULATOR ............................................................................12 4.3 LOAD SWITCHING DEVICES ...........................................................................................13 4.3.1 CONTACTORS ...........................................................................................................13 4.3.2 CHARGED SPRING BREAKERS ...............................................................................13 4.3.3 AIR CIRCUIT BREAKERS (ACB) ...............................................................................13 4.3.4 MOTOR OPERATED BREAKERS .............................................................................13 4.3.5 MANUALLY OPERATED BREAKERS .......................................................................13

SETTING UP THE SYSTEM .......................................................................... 15

5.1 THE BASICS ......................................................................................................................15 5.2 TAKING CONTROL ...........................................................................................................15 5.2.1 INITIAL SETUP ...........................................................................................................15 5.2.2 LOAD ACCEPTANCE TEST .......................................................................................16 5.2.3 FULL LOAD TEST.......................................................................................................16 5.2.4 QUAD DROOP SET-UP..............................................................................................16 5.2.5 INTRODUCING THE DSE ANALOGUE GOVERNOR CONTROL ............................17 5.2.6 INTRODUCING THE DSE ANALOGUE AVR CONTROL ..........................................21 5.3 TESTING THE CONTROLS...............................................................................................25 5.3.1 TESTING ANALOGUE SPEED AND VOLTAGE CONTROL .....................................25 5.3.2 SYNC CHECKS ..........................................................................................................27 5.4 SYNCHRONISING .............................................................................................................28 5.5 ADJUSTING RESPONSE ..................................................................................................29 5.5.1 ANALOGUE SCHEME ................................................................................................29 5.5.2 PULSE SCHEME ........................................................................................................30 5.6 LOAD SHARING ................................................................................................................31 5.7 ADJUSTING RESPONSE ..................................................................................................31 5.7.1 ANALOGUE SCHEME ................................................................................................31 5.7.2 PULSE SCHEME ........................................................................................................31 5.8 PARALLEL WITH MAINS SUPPLY ..................................................................................32 5.8.1 5510.............................................................................................................................32 5.8.2 5520.............................................................................................................................32 5.8.3 5560.............................................................................................................................33 5.8.4 550 / 555 / 557 ............................................................................................................34 5.8.5 556...............................................................................................................................34

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1 INTRODUCTION
Load share systems can be complex and confusing when first approached. The purpose of this guide is to highlight the steps needed to design the system, specify the components, test and commission the final solution. The guide deals with this in two sections; the design stage or thinking stage and then the test/commission stage or Doing stage. 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 following DSE documents:5000 series controllers Guide to Synchronising and Load Sharing PART I & II 5xxx configuration software manual 5510 Operators Manual 5520 Operators Manual 5560 Operators Manual Link5000plus Software Manual 500 series controllers Guide to Synchronising and Load Sharing PART 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 / load sharing system. This is intended as a guide only and is not a substitute for in depth knowledge of synchronising 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 to governors and interfacing to Automatic voltage regulators. Design your panel and system wiring. DSE can assist with your specific questions on this but cannot design your panel for you. If you want a panel designing, please contact DSE Technical Support Department who may be able to recommend a third party panel designer / builder capable of producing a synchronising / load sharing system. Check / adjust the DSE modules configuration using the configuration software. If it is a Multiset system, ensure that the settings for Multiset Comms Link are correctly configured 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 site commissioning. Set up the governor and AVR as detailed in their respective manufacturers handbooks. Before synchronising sets for the first time, double check that all the Bus wiring is correct and that the controllers initial settings are suitable. This may include lowering the settings for gain and stability in the synchronising, voltage matching and load control sections. Details of ways to verify these are included in the section entitled Controller commissioning adjustments.
Should you have any queries arising from this manual please contact our Technical Department:

INTERNATIONAL TEL: +44 (0) 1723 890099 INTERNATIONAL FAX: +44 (0) 1723 893303 E-mail: support@deepseaplc.com Web: http://www.deepseaplc.com

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2.1

CLARIFICATION OF NOTATION AND TERMINOLOGY USED WITHIN THIS PUBLICATION.

NOTE: CAUTION! WARNING! Highlights an essential element of a procedure to ensure correctness. Indicates a procedure or practice which, if not strictly observed, could result in damage or destruction of equipment. Indicates a procedure or practice, which could result in injury to personnel 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 party without prior written permission. Compliant with BS EN 60950 Low Voltage Directive Compliant with BS EN 50081-2 EMC Directive Compliant 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. Governor

Automatic Voltage Regulator. Fitted to the alternator to regulate the output of the generator. Engine Speed Governor. Fitted to the engine to electronically control the speed of the engine. When load is applied to a generator fitted with a droop governor / AVR, the speed/voltage will drop. This is called droop. It is common for a droop set to drop between 3% and 10% in speed / voltage from no load applied to full load applied. A governor with no speed droop, or where speed droop is disabled is known as an isochronous governor. The engine speed remains constant so long as the load levels are within the sets capability. To get the supplies identically matched, ready for paralleling. Connect two or more supplies together. These supplies must be in synchronism before this can occur. centre point of an electronic pot, digital resistance or AVR/Governor. The nominal voltage or frequency of the system i.e. 230V 50Hz. This is not necessarily the same as the Datum. (i.e. when droop governors/AVRs are used, the datum will be higher than the nominal ) The AC distributed power supply of a power generation company. Often also called the grid, or utility supply.

Droop

Isochronous Synchronise Parallel Datum

Nominal

Mains 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 system requirements. This list is not exhaustive; please call us if you have requirements not detailed in the following sections.

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 the load. 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 full load rating. Sets are automatically started and stopped depending upon load levels allowing economic use of the 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 shift detection components are fitted when paralleling a generating set with the mains supply. Additional equipment of this type is normally specified by the local electricity Supply Company. This protects against the generator feeding the mains grid in the case of a mains failure. However, in applications of this type, where parallel time is kept to a minimum, 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 load switching 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, and closed onto the load. When the mains supply returns, there will be NO break in supply to the load while a ramped transfer takes place. This system can also be configured to start the set upon rising load levels to allow the set to be used 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 to the 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 stop automatically upon rising/falling load levels. When the mains supply returns, there will be NO break in supply to the load while a ramped transfer takes place. This system can also be configured to start the set upon rising load levels to allow the sets to be used 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 shift detection components are fitted when paralleling a generating set with the mains supply. Additional equipment of this type is normally specified by the local electricity Supply Company. This protects against the generator feeding the mains grid in the case of a mains failure. However, in applications of this type, where parallel time is kept to a minimum, 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 to provide backup to multiple mains supplies, controlled with 5560 modules. When a mains supply fails, the set is started, and closed onto the generator bus. The generator bus is then closed to feed the load. Should more than one mains supply fail, their appropriate loads are also transferred to the genset. When a mains supply returns, there will be NO break in supply to the load while a ramped transfer takes place. If all mains supplies return together then the mains priority is used to determine which mains transfer first, each mains supply is paralleled with the genset and the appropriate load is ramped onto the mains supply, until all 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 used to provide backup to multiple mains supplies, controlled with 5560 modules. When a mains supply fails, the sets are started, synchronised and paralleled together. The generator bus is then closed to feed the load, the sets sharing power equally as a percentage of their full load rating. Sets are automatically started and stopped depending upon load levels allowing economic use of the available generators. Should more than one mains supply fail, their appropriate loads are also transferred to the gensets. When a mains supply returns, there will be NO break in supply to the load while a ramped transfer takes place. If all mains supplies return together then the mains priority is used to determine which mains transfer first, each mains supply is paralleled with the gensets and the 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 application you need to ask the following questions. Use this list as a checklist and tick the boxes once each item 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 and
shutdown 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. For assistance, 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 the analogue governor output or the CAN interface (when used in conjunction with a suitable electronic 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 the engine speed via the governor speed bias input. The governor input needs to accept the 0-10V DC signal used. DSE has detailed the connection to many governor systems commonly found in the industry please refer to The guide to Synchronising 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 the DSE CAN controller for synchronising and load sharing purposes. This replaces the requirement to connect 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 to Synchronising and load share PART 2.

4.2

AUTOMATIC VOLTAGE REGULATOR

DSE 55xx modules interface to the AVR on the alternator using either the analogue AVR output. 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 the engine speed via the governor speed bias input. The AVR input needs to accept the 0-10V DC signal used. DSE has detailed the connection to many AVR systems commonly found in the industry please refer to The guide to Synchronising and 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 in parallel. 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 the close signal being given to ensure the phase or the supplies has not changed too greatly after the closing signal has been given. For instance a change of load will affect the phase. Cycle time 50Hz system 60Hz system 20.0 ms 16.7 ms Max load switch closing time 100 ms 83 ms

NOTE: - The closing time of any load switching device slave relays should also be taken into account. For instance, plug in relays typically used in generating set control panels 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 paralleling applications. (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 when breaker operation is required, the spring is released which operates the closing action of the device. Typically, the spring is charged when the undervolts input is energised, normally when the set is first 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 to choose 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 the excessive amount of time that the breaker takes to motor into position before the closing process can be completed. Care should be taken to choose a motor operated breaker that the manufacturer 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 and must not be 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 is ready for setting up, testing and commissioning.

5.1

THE BASICS

It will not be possible to commission a load sharing system unless the basics are correct to begin with. The setup of the module is covered in the relevant manuals and is outside the scope of this document. However, before proceeding the following should be checked. Use this section as a checklist and tick the boxes when each item has been appraised.

System drawings to ensure correct connection of the module and other

components

Module configuration to ensure correct settings in the unit for the application
AFTER these have been confirmed, the next stages are:-

Connect the system up Configure the module Check to ensure correct settings on the MSC (Multi Set Comms) Link.
NOTE:-DO NOT CONNECT the Governor or AVR interface (or P120 / P121) to the governor and AVR at this time.

5.2
5.2.1

TAKING CONTROL
INITIAL SETUP

The first stage of testing is to set up the governor correctly and then to allow the DSE module to take control over it. Start the engine and follow the governor manufacturers recommended start up procedure. This will result in the engine running at the correct speed (i.e. 50Hz). Following the manufacturers recommendations 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 manufacturers recommendations 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 acceptance tests) 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 the connections to the CTs and that the CTs are the right way round. NOTE:- Occasionally CTs are manufactured incorrectly - The terminal designations are reversed ie S1/S2 or P1/P2 are transposed! Remove the load and check that the response is acceptable. The engine should drop the load and return 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 is achieved. Some governors and AVRs also have a DERIVATIVE setting that can be adjusted. Refer to the manufacturer 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 will take. If changes are required, repeat above set-up procedure.

5.2.4

QUAD DROOP SET-UP

When the governor is setup satisfactorily, the quadrature droop on the AVR must be set up correctly. 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 the governor 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 in speed allowed (gain). Connect the analogue governor output A/B terminals to the engine governor speed control or sync/load share terminals as required.

Full connection details and suggested switch setting for many common governor systems can be found 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 the governor being used. SW1 sets the centre or off-set speed, and SW2 sets the amount of swing 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 controller at this time.

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

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SETTING SW1 (CENTRE) SW1 sets the centre point 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 analogue governor output, the engine speed may have changed. Using 5xxx configuration software, go to the Re-calibrate | Sync + load control | Governor/AVR interface tab as shown opposite. SW1 should be adjusted until the engine speed is as close as possible to the desired speed. Then trim the engine speed to the exact value (if required) using the speed trim potentiometer on the engine governor.

Once the speed has been set, increasing SW1 will increase or decrease the speed. If the speed increased when SW1 is turned clockwise, then the Governor output reversed tick box on the Edit Config | Generator | Sync / load control | Auto sync tab of 5xxx configuration software should be left un-ticked. If however the speed had decreased when SW1 was increased, then the Governor output reversed tick box should be ticked.

NOTE: - If the generator speed remains unchanged when SW1 is adjusted, the DSE module has 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 DSE module is the wrong way round, it could give the appearance of a governor that requires the Governor output reversed field to be ticked. Therefore, care should be taken to make sure that the wiring is correct.

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550/555/557 controller The generator should be kept running but off load (breaker / contactor open). The P120 governor interface should be disconnected from the 55x controller, but connected to the governor. The speed of the generator may have changed. SW1 on the P120 should be adjusted until the engine speed is as close as possible to the desired speed. E.g., the desired speed may be 50Hz but changing SW1 one notch may alter the speed from 49.8Hz to 50.2Hz. This means that one position of the switch changes the engine speed by 0.4Hz. Once SW1 has been adjusted to set the speed as close as possible to the desired speed, the speed trim potentiometer on the governor should be adjusted to tune the engine speed. Once the speed has been set, adjusting SW1 on the P120 interface one position clockwise will increase or decrease the speed. Using the above example, the speed changes by 0.4 Hz for every position SW1 changes. If the speed had increased when SW1 was turned clockwise, then the Governor output reversed tick box on the Edit config | Generator | Sync / load control | Auto sync tab of the P810 software should be left un-ticked. If however the speed had decreased when SW1 was turned clockwise, then the Governor output reversed tick box should be ticked.

NOTE:- If the generator speed remains unchanged when SW1 is adjusted, the P120 has 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 way round it could give the appearance of a governor that requires the Governor output reversed field to be ticked. So care should be taken to make sure that the wiring is correct.

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SETTING SW2 (RANGE) SW2 will set how much range the analogue governor output (or P120 output) has around the centre 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 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 50Hz. SW1 is increased by 6 positions until the generator output is 52.5Hz. 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 the Governor. Typically, a speed range of 2.5 to 3 Hz is required, therefore in this example set SW2 to 6.

NOTE:- 5510/5520 use software settings for SW1 and SW2 with settings possible of 0.0-10.0 in steps of 0.1 550/555/556 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 the AVR 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 in voltage allowed (gain). Connect the analogue AVR output A/B terminals to the AVR voltage control or sync/load share terminals as required.

Full connection details and suggested switch setting for many common AVR systems can be found in The guide to sync and load sharing PART 2. 550/555/556 controller The two rotary switches on the P121 should have been set to the correct values for the governor being used. SW1 sets the centre or off-set voltage, and SW2 sets the amount of range 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 controller at this time.

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

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SETTING SW1 (CENTRE) SW1 sets the centre point of the analogue AVR output (or P121). 5510/5520 controller The generator should be kept running but off load (breaker / contactor open). After connection of the analogue AVR output, the generator voltage may have changed. Using 5xxx configuration software, go to the Re-calibrate | Sync + load control | Governor/AVR interface tab as shown opposite. SW1 should be adjusted until the generator output is as close as possible to the desired voltage. Then trim the voltage to the exact value (if required) using the speed trim potentiometer on the AVR.

Once the voltage has been set, increasing SW1 will increase or decrease it. If the voltage increases when SW1 is turned clockwise, then the AVR output reversed tick box on the Edit Config | Generator | Sync / load control | Auto sync tab of 5xxx configuration software should be left un-ticked. If however the voltage had decreases when SW1 was increased, then the AVR output reversed tick box should be ticked.

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

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

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550/555/557 controller The generator should be kept running but off load (breaker / contactor open). The P121 governor interface should be disconnected from the 55x controller, but connected to the AVR. The voltage of the generator may have changed. SW1 on the P121 should be adjusted until the generator 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 trim potentiometer on the AVR should be adjusted to tune the alternator output. Once the voltage has been set, adjusting SW1 on the P121 interface one position clockwise will increase or decrease the output. If the voltage increases when SW1 is turned clockwise, then the AVR output reversed tick box on the Edit config | Generator | Sync / load control | Auto sync tab of the P810 software should be left un-ticked. If however the voltage decreases when SW1 is turned clockwise, then the AVR output reversed tick box should be ticked.

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

NOTE: - If the wiring between the AVR and the DSE module is the wrong way round, it could give the appearance of an AVR that requires the AVR output reversed field to be ticked. 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 range the analogue AVR output (or P121 output) has around the centre 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 voltage by 35V (230V system) and note how many positions 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 is 265V. 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 the AVR. Typically, a voltage range of 30V-35V (230V nominal system) is required, therefore in this example set SW2 to 3.

NOTE:- 5510/5520 use software settings for SW1 and SW2 with settings possible of 0.0-10.0 in steps of 0.1 550/555/556 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 generator on 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 load on the Edit config | Generator | Sync / load control | Auto sync tab of the configuration software to Reset to nominal. Set the nominal voltage and nominal frequency on the Generator volts alarms and Generator frequency alarms tabs of the configuration software 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 load switch device. 5510 / 5520 modules - The breaker/contactor can be closed either by using the transfer to gen fascia button, activating an input configured to Transfer to gen or 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 input configured to Transfer to gen or by using the SCADA tab on the PC configuration software. The load 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 be zero.

Stop the generator. Using the PC configuration software: Set the nominal voltage on Generator volts alarms tab to 220 V i.e. 10 Volts lower. Set the nominal frequency on Generator frequency alarms tab 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 the generator, reset the nominal voltage and frequency back to the desired values using the configuration 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 been completed satisfactorily.

WARNING!: Sync checks MUST be carried out on each breaker before it is closed for the first time onto a live circuit. As a useful commissioning aid, configure one of the LEDs on all of the DSE modules on the common bus to Check sync. On a multi set system, start one of the generators, and close onto a dead bus. Its Check sync LED should illuminate, or if the module is a 5520/555/557 (single set parallel with mains) ensure the 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 display on the module. The synchroscope will indicate the difference in Voltage, frequency and phase angle as follows.

Zero phase angle window Slowly moving bar to indicate phase angle Using a fast reacting volt-meter, or light bulb, check that there is a near zero potential difference across 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 for wiring 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. After the above tests have been completed satisfactorily, stop the generator and re-enable the breaker/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) or by 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 gen fascia button, activating an input configured to Transfer to gen or 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 input configured to Transfer to gen or by using the SCADA tab on the PC configuration software. The load switch should close on to a dead bus, and stay closed.

5.5
5.5.1

ADJUSTING RESPONSE
ANALOGUE SCHEME

The Analogue scheme is used when the governor / AVR is controlled directly from the analogue outputs (or P120/P121) of the DSE controller. As the DSE controller synchronises the generator, the response of the generator is adjusted by increasing or decreasing the Stability settings on the Re-calibrate | Sync + load control | Synchroniser / volts match tab of the configuration software. There are two stability settings, one setting for the governor and one setting for the AVR. The target speed is set via the Slip frequency, and should be set within the check sync window found on the Edit Config | Generator | Sync / Load control | Check sync tab of the configuration software.

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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5.5.2

PULSE SCHEME

The pulse scheme is used when the governor / AVR are controlled by raise/lower relay outputs from the DSE controller. As the DSE controller synchronises the generator, the response of the generator is adjusted using the Response and Stability sliders, one set for the governor and the other set for the AVR. The response is how many pulses there are per second and the stability is the length of the pulse. However if the difference between the target and actual is very small, the pulse rate is automatically reduced.

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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 or the voltage setting of the AVR. The system will maintain the nominal voltage and nominal frequency set on the Edit config | Generator | Generator volts alarms and Generator frequency alarms tabs of P810 software.

5.7
5.7.1

ADJUSTING RESPONSE
ANALOGUE SCHEME

The Analogue scheme is used when the governor / AVR is controlled directly from the analogue outputs (or P120/P121) of the DSE controller. The response of the generator whilst load sharing is adjusted using the Gain and Stability sliders on the Re-calibrate | Sync + load control | Load Control tab of the configuration software. There are two gain and stability settings, one for the governor and one for the AVR. Each time the settings are adjusted the load must be changed to test the new settings and to make sure that the system has not become unstable.

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

5.7.2

PULSE SCHEME

The pulse scheme is used when the governor / AVR are controlled by raise/lower relay outputs from the DSE controller. The response of the generator whilst load sharing is adjusted using the Response and Stability sliders, one set for the governor and the other set for the AVR. The response is how many pulses there are per second and the stability is the length of the pulse. However if the difference between the target and actual is very small, the pulse rate is automatically reduced.

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

PARALLEL WITH MAINS SUPPLY

The 5510, 5520, 5560, 550, 555, 556 and the 557 are all capable of running in parallel with the mains. Once the generator has synchronised and closed the generator switching device the function of the DSE controller is varied by both controller type and configuration. The following sections detail the possibilities:

5.8.1

5510

The controller will instruct the generator to product a fixed amount of power. The generator will maintain the kW and power factor output that is set on the Recalibrate, Sync + load control, Load Levels tab of the 5xxx configuration software. If the load is less than this output, the remainder will be exported to the mains. Similarly, if the load is greater than the generator output, the mains will supply the 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 Recalibrate, Sync + load control, Load Levels tab of the 5xxx configuration software. If the load is less than this output, the remainder will be exported to the mains. Similarly, if the load is greater than the generator output, the mains will supply the remainder. MAINS MODE The DSE module will control the generator(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 5xxx configuration software. This level can be a mains import or export level. If the load levels are such that the generators reach 100% of their rating, and the mains supply is not being held to the levels set, the DSE controller will activate the Insufficient capacity alarm and the mains will supply the remainder of the load. NOTE:- When in mains mode, the generators will NEVER be instructed to produce a leading 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

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 Recalibrate, Sync + load control, Load Levels tab of the 5xxx configuration software. If the load is less than this output, the remainder will be exported to the mains. Similarly, if the load is greater than the generator output, the mains will supply the remainder. MAINS MODE The DSE module will control the generator(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 5xxx configuration software. This level can be a mains import or export level. If the load levels are such that the generators reach 100% of their rating, and the mains supply is not being held to the levels set, the DSE controller will activate the Insufficient capacity alarm and the mains will supply the remainder of the load. NOTE: - When in mains mode, the generators will NEVER be instructed to produce a leading 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 in parallel with one mains supply at a time. Therefore, a priority system exists on the 5560 controller to 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 following DSE 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 the generator to product a fixed amount of power. The generator will maintain the kW and power factor output that is set on the Recalibrate, Sync + load control, Load Levels tab of the P810 configuration software. If the load is less than this output, the remainder will be exported to the mains. Similarly, if the load is greater than the generator output, the mains will supply the remainder. NOTE: - Changes to this page are written to the unit automatically. Do not use the write button on the Config Manager tab.

5.8.5

556

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, Load Levels tab of the P810 configuration software. If the load is less than this output, the remainder will be exported to the mains. Similarly, if the load is greater than the generator output, the mains will supply the remainder. MAINS MODE The DSE module will control the generator(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 import or export level. If the load levels are such that the generators reach 100% of their rating, and the mains supply is not being held to the levels set, the DSE controller will activate the Insufficient capacity alarm and the mains will supply the remainder of the load. NOTE: - When in mains mode, the generators will NEVER be instructed to produce a leading 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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