057-047 Design Guide

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

Deep Sea Electronics Plc
Highfield House
Hunmanby
North Yorkshire
YO14 0PH
ENGLAND
Sales Tel: +44 (0) 1723 890099

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E-mail: Sales@Deepseaplc.com
© Deep Sea Electronics Plc

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

TABLE OF CONTENTS
Section Page
1 INTRODUCTION .............................................................................................. 4
2 STEP BY STEP GUIDE.................................................................................... 4
2.1 CLARIFICATION OF NOTATION AND TERMINOLOGY USED WITHIN THIS
PUBLICATION. ...............................................................................................................................5
3 BASIC SYSTEM ARRANGEMENT ................................................................. 7
3.1.1 PRIME POWER ............................................................................................................7
3.1.2 SINGLE MAINS SUPPLY..............................................................................................8
3.1.3 MULTIPLE MAINS SUPPLIES ......................................................................................9
4 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
5 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

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 500 series controllers

Guide to Synchronising and Load Sharing Guide to Synchronising and Load Sharing
PART I & II PART I & II
5xxx configuration software manual P810 Software Manual
5510 Operators Manual 550 Operators Manual
Link5000plus Software 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 module’s 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

2.1 CLARIFICATION OF NOTATION AND TERMINOLOGY USED WITHIN
THIS PUBLICATION.
Highlights an essential element of a procedure to ensure

NOTE: correctness.
Indicates a procedure or practice which, if not strictly observed,
CAUTION! could result in damage or destruction of equipment.
Indicates a procedure or practice, which could result in injury to
WARNING! 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
D Year 2000 Compliant
Two crossing wires with no interconnection between the two.
Three wires, all connected together
Connections to the 55x controller’s battery supply negative terminal,

usually the earthed battery –ve terminal.
Automatic Voltage Regulator. Fitted to the alternator to regulate the
A.V.R.
output of the generator.
Engine Speed Governor. Fitted to the engine to electronically control
Governor
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
Droop
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
Isochronous known as an isochronous governor. The engine speed remains
constant so long as the load levels are within the set’s capability.
Synchronise To get the supplies identically matched, ready for paralleling.
Connect two or more supplies together. These supplies must be in

Parallel
synchronism before this can occur.
‘centre’ point of an electronic pot, digital resistance or
Datum
AVR/Governor.
The nominal voltage or frequency of the system i.e. 230V 50Hz. This
is not necessarily the same as the Datum.
Nominal
(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.
Mains supply
Often also called the ‘grid’, or ‘utility’ supply.

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.

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.

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.

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.

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.

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 ECU’s.
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.

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 Max load switch
closing 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 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.

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 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 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.

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.

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’.

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.

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.

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.

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’.
• 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’.

SETTING SW1 (CENTRE)
SW1 sets the centre point of the analogue AVR output (or P121).
5510/5520 controller
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.

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.

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.

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.

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.

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 9 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.

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.

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 ADJUSTING RESPONSE
5.5.1 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.

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.

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 ADJUSTING RESPONSE
5.7.1 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
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.
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.

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 ‘Re-
calibrate’, ‘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
software.
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%

5.8.3 5560

BUS MODE
software.
remainder.
MAINS MODE
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.
NOTE: - When in mains mode, the generators will NEVER be instructed to produce a
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 5560’s 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 5560’s in a ‘multi-mains’ system must be version 6 or above.

5.8.4 550 / 555 / 557
These controllers will instruct the

generator to product a fixed amount of
power.

Levels’ tab of the P810 configuration
software.

remainder.
5.8.5 556
Bus mode
power factor output that is set on the
‘Re-calibrate’, ‘Sync + load control’,
‘Load Levels’ tab of the P810

generator output, the mains will supply
the remainder.
MAINS MODE
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.
NOTE: - When in mains mode, the generators will NEVER be instructed to produce a

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DEEP SEA ELECTRONICS PLC

Load Share System Design and

Using the DSE 55xx range of Products

Authors: - John Ruddock

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

Sales Tel: +44 (0) 1723 890099

© Deep Sea Electronics Plc

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

057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 3

5000 series controllers 500 series controllers

2 STEP BY STEP GUIDE

4 057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM

Highlights an essential element of a procedure to ensure

D Year 2000 Compliant

Two crossing wires with no interconnection between the two.

Three wires, all connected together

Connections to the 55x controller’s battery supply negative terminal,

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

Connect two or more supplies together. These supplies must be in

057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 5

3.1.1 PRIME POWER

The generators are controlled by 5510 or 550 controllers.

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

NOTE: - It is recommended that ROCOF (Rate of change of frequency) or vector shift

A single generating set is used to provide backup to the

When the mains supply returns, there will be NO break

Multiple generating sets are used to provide backup to

Sets can also be configured to start and stop

When the mains supply returns, there will be NO break

8 057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM

NOTE: - It is recommended that ROCOF (Rate of change of frequency) or vector shift

A single 5510 controlled generating set is used to

Should more than one mains supply fail, their

When a mains supply returns, there will be NO break in

If all mains supplies return together then the mains

057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 9

In this system, the generators are controlled by 5510 controllers.

Should more than one mains supply fail, their

When a mains supply returns, there will be NO break in

If all mains supplies return together then the mains

10 057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM

 Are there any special operating conditions to take into account?

057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 11

4.1.1 ANALOGUE OUTPUT CONTROL / P120 CONTROL

4.1.2 CAN CONTROL (5510 / 5520 ONLY)

4.2 AUTOMATIC VOLTAGE REGULATOR

12 057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM

4.3.2 CHARGED SPRING BREAKERS

4.3.3 AIR CIRCUIT BREAKERS (ACB)

4.3.4 MOTOR OPERATED BREAKERS

4.3.5 MANUALLY OPERATED BREAKERS

057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 13

5.1 THE BASICS

 System drawings to ensure correct connection of the module and other

 Connect the system up

5.2 TAKING CONTROL

5.2.1 INITIAL SETUP

057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 15

NOTE:- Occasionally CTs are manufactured incorrectly - The terminal designations

5.2.3 FULL LOAD TEST

5.2.4 QUAD DROOP SET-UP

16 057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM

5510 / 5520 controller

057-047 Load Share System Design and Commissioning ISSUE2 25/7/07 AM 17

D Year 2000 Compliant

Are there any special operating conditions to take into account?

System drawings to ensure correct connection of the module and other

Connect the system up