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Load Share Design and Commisioning PDF
Load Share Design and Commisioning PDF
E-mail: Sales@Deepseaplc.com
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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
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
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:-
• 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
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
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.
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.
SINGLE GENERATOR
In this system, the generator is controlled by 5510 or 550 load share controller.
The mains controllers/ATS are 5560 controllers.
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?
• 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.
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.
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’.
• 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.
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).
Manually operated breakers cannot be closed in the time required of a synchronising system and
must not be used.
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.
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.
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.
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.
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.
• 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’.
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).
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 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.
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.
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.
• 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’.
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).
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 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.
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.
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.
550/555/557 only - You can now connect the P120 and P121 interfaces to the 55x controller.
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.
• 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.
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.
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.
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.
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.
The ‘Analogue scheme’ is used when the governor / AVR is controlled directly from the analogue
outputs (or P120/P121) of the DSE controller.
NOTE:- Changes to this page are written to the unit automatically. Do not use the write
button on the Config Manager tab.
The ‘Analogue scheme’ is used when the governor / AVR is controlled directly from the analogue
outputs (or P120/P121) of the DSE controller.
NOTE:- Changes to this page are written to the unit automatically. Do not use the write
button on the Config Manager tab.
NOTE:- Changes to this page are written to the unit automatically. Do not use the write
button on the Config Manager tab.
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
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.
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.
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.
For further details regarding the use of multiple mains supplies, you are referred to the following
DSE documentation:
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.
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.