CDVR Troubleshooting

October 30, 2007

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Outline

• Troubleshooting
– If operation is not as expected
– Excitation loss (reverse kvar)
– Generator over voltage
– Generator under voltage
– No generator voltage
– Exciter diode monitor fault

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Outline (continued)

• Troubleshooting
– Over excitation fault
– Loss of sensing
– Field over current
– Internal Memory Failure
– Internal Watchdog Failure
– Unstable Voltage
– Poor Transient Response

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 CAUTION

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If Operations is not as Expected:

– Check for Alarms or Shutdown Faults
– If Fault LED is lit Continuously Alarm Output Drive Active
– If Fault LED is Flashing Shutdown Output Drive Active
– Open Communications with CDVR to determine what Alarm /
Shutdown is active
– Alarm Signal Indicator Visible on all Screens
– Go to Metering Screen, look at Alarms area
– Check Programmable Settings

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 CAT PC Metering Screen

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 CAT PC Protection Screen

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If Excitation Loss(Reverse kvar) has Occurred:

– Verify programmable settings are consistent with application
– Check wiring of generator voltage (P12 – 10 to 12) and Current
Sensing (P12 – 1 & 2)
– Check phase rotation, if not consistent with wiring diagram,
modify connections
– Check other paralleled generators or voltage sources for over
voltage (this can cause reverse var flow into generator)
– Replace regulator

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If Generator Over Voltage has Occurred:

– Check wiring of generator voltage sensing (P12 –10 to 12)
– Verify that the generator over voltage fault settings are correct
– Verify that voltage adjustment is not set too high
– Verify that sensing PT (if used) has correct turns ratio
– Verify that sensing PT fuses (if used) have not opened
– High voltage may occur if operating in droop mode with
capacitive load or if CT connection is backwards or wrong phase
rotation
– High voltage may occur if operating in line drop compensation
mode with a large generator load
– Verify auxiliary input voltage is not too high
– Replace regulator

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If Generator Under Voltage has Occurred:

– Check wiring of generator voltage sensing (P12 –10 to 12)
– Verify that the generator under voltage fault settings are correct
– Verify that voltage adjustment is not set too low
– Verify that the generator is running at rated speed
– Verify that the under frequency setpoint (knee frequency) is not
greater than generator frequency
– Verify that sensing PT (if used) has correct turns ratio
– Check for correct input power
– Low voltage may occur if operating in droop mode with high
inductive load
– Verify auxiliary input voltage is not too low
– Replace regulator

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If No Generator Voltage is Present:

– Check wiring
– Verify that the generator is running at rated speed
– Verify that residual voltage applied to the power input is at least
6Vac or greater
– Verify that the fuse is not open
– Verify that CDVR is connected to 24Vdc control power
– Verify that common alarm / shutdown LED is not flashing

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If No Generator Voltage is Present and an Exciter Diode Monitor

Fault has Occurred:
– Stop machine
– Insure power input to CDVR has been removed, unplug P6
– Refer to generator manual for instructions on checking the
rotating exciter diodes
– If no fault is found with rotating exciter diodes, the EDM trip value
may be too low
– Increase EDM trip value to a level greater than the ripple current
under normal operation
– If rotating exciter diodes are at fault, repair, reinstall P6 then
reset the CDVR using the Fault Reset contact input or cycle the
24Vdc control power

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If No Generator Voltage is Present and an Over Excitation Fault has

Occurred:
– Stop machine
– Check generator and load conditions for a fault that could cause
excessive exciter field current
– If no fault is found, reset the CDVR using the Fault Reset contact input
or cycle the 24Vdc control power
– Verify the over excitation settings are properly adjusted for the
generator, set slightly above the requirement of the application but not
so high as to render the protection ineffective
– If an exciter diode fault has occurred, the instantaneous trip value of
28A may have been reached. The EDM fault will not indicate this, due to
a 5 sec time delay
– SR4 &SR4B generator require up to 12Adc for full load. A 10 second
setting is required to insure 300% short circuit requirements

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If No Generator Voltage is Present and a Loss of Sensing Fault has

Occurred:
– Stop machine
– Check wiring
– Check generator and load conditions for a fault that could cause
sensed voltage to be low
– If sensing potential transformers are used, verify that they are
functional and have not blown a fuse
– Once fault is repaired, reset the CDVR using the Fault Reset
contact input or cycle the 24Vdc control power

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If No Generator Voltage is Present and a Field Over Current Fault

has Occurred:
– Stop machine
– Check wiring
– Check generator and load conditions for a fault that could cause
a field over current
– A field over current fault occurs when output current exceeds
28A (approximately)
– Once fault is repaired, reset the CDVR using the Fault Reset
contact input or cycle the 24Vdc control power

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If No Generator Voltage is Present and an Internal Memory Failure

Fault has Occurred:
– Try resetting the CDVR using the Fault Reset contact input or
cycle the 24Vdc control power
– If after resetting the CDVR, if another Internal Memory Failure
fault occurs, replace regulator

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• If No Generator Voltage is Present and an Internal Watchdog Failure

Fault has Occurred:
– Try resetting the CDVR using the Fault Reset contact input or
cycle the 24Vdc control power
– If after resetting the CDVR, if another Internal Watchdog Failure
fault occurs, replace regulator

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• Unstable Voltage:
– Verify that the governor for the engine is operating properly
– Verify that the sensing and power leads are connected securely
– Verify that the CDVR stability range is set to the proper range
– Verify that the stability level (Kg) is properly set

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• Poor Voltage Response to a Transient Load:

– Verify that the governor for the engine is operating properly
– Verify that the CDVR stability range is set to the proper range
– Verify that the stability level is properly set
– Tune the CDVR for the application

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• CDVR PID Tuning:

– Perform a “step of reference” test with 1 or 2% steps
– Look at terminal voltage response with chart recorder
– Determine if voltage response is acceptable
• Rise time
• Over shoot
• Settling time
• Damping
– If not acceptable, tune the CDVR for the application
– Once “step of reference” test is suitable, verify load application /
rejection performance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Step of Reference Test

Rise Time

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Step of Reference Test

Over Shoot

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Step of Reference Test

+/- 2%

Settling Time

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Step of Reference Test

Damping

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Troubleshooting

• CDVR PID Tuning:

– Examples of “step of reference” test results
– Tests performed on 300kW, 240V, 60Hz AREP generator
• Factory defaults
• PID calculator
• “Magic” PID values = 80, 20 and 10

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Default PID = 200, 600, 30 with Kg = 50

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Default PID = 200, 600, 30 with Kg = 25

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Default PID = 200, 600, 30 with Kg = 10

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Default PID = 200, 600, 30 with Kg = 1

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 PID Calculator, T’do = 2s, Te = 0.1s
PID &Kg = 25, 43, 2.7 & 50

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 PID Calculator, T’do = 2s, Te = 0.1s
PID &Kg = 25, 43, 2.7 & 200

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 PID Calculator, T’do = 1.5s, Te = 0.1s
PID &Kg = 25, 51, 2.6 & 200

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 PID Calculator, T’do = 1.0s, Te = 0.1s
PID &Kg = 42, 100, 4.5 & 200

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 “Magic” PID Values = 80, 20, 10
Kg = 50

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 PID Tuning Conclusion

• Must adjust Kg to achieve best results

• Factory Default Values result in “OK” performance
• PID Calculator gives very good results but must know T’do and Te
• “Magic” PID values also very good and it is simple
• Once “step of reference” test is suitable, verify load application /
rejection performance

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 Information Needed If Replacement of CDVR is Selected

• When sending back a CDVR, please provide the following:

– Detailed statement of problem including
• Symptoms of the failed CDVR
• Genset configuration and ratings
• Operating Conditions (kW, voltage, current … etc)
• Run time
• Anything unique about the installation
• Did anything of significance occur just before the failure
occurred? (i.e. sparks, re-wiring, etc.)
• Is there any mechanical damage to the CDVR or mounting?

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

 QUESTIONS?

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007