KG-1500

Overview
Hardware – I/O’s
KG-1500

Graphical display 3" size (128x64 )

3 phase generator voltage
3 phase generator current
3 phase mains or bus voltage
1 phase mains or earth current

10 digital inputs
11 digital outputs (relays)
7 analog inputs
2 analog output (+/- 10V or +/- 20mA or PWM)
Service port (ToolKit / KRM)
2 CAN interface (load share and J1939)
D+ connection
1 RS-485 interface with Modbus
1 MPU input
2 |
Application
Single Unit Mains Parallel
 Engine start / stop
 Generator protection 3ph
 AMF (auto mains failure) 1ph
 Generator control:
− Frequency / active power o/c

− Voltage / power factor

 Parallel to mains o/c
 Full Generator Breaker Control
3ph
 Full Mains Breaker Control
3ph
 Inbuilt Neutral Interlocking logic
 Run-Up Sync SC
AVR

3 |
Application
Multiple Unit Isolated Parallel
 Engine start / stop
 Generator control / protection
 Frequency / load sharing
 Voltage / reactive load sharing
 Sequencing (Load Dependent Start /Stop: LDSS)
 Maximum 16 units in parallel
 Inbuilt Neutral Interlocking logic
 Run-Up Sync

KG-1500 KG-1500 KG-1500

4 |
Voltage and Current sensing Generator and Mains
3Ph4W (3phase, 4wire) 3Ph3W (3phase, 3wire)
1-, 2- and 3-phase CT arrangement possible & configurable for each phase

1Ph3W (1phase, 3wire) 1Ph2W (1phase, 2wire)

only 2-phase CT possible only 1-phase CT possible

5 |
AC Generator sensing
True RMS Voltage Sensing True RMS Current Sensing
 4-phase (L1, L2, L3, Neutral)  3-phase
 100 and 400 V input  Class 1 accuracy
 Frequency measurement
 Field rotation detection
 Class 1 accuracy

True RMS Auxilliary Current Sensing Power Sensing

 Configurable as mains CT or Generator ground  True RMS power measuring
fault CT
 Real and reactive power
 Power factor
 Energy counters kwh and varh
6 |
AC Mains / Busbar sensing
True RMS Voltage Sensing True RMS Current Sensing
 4-phase (L1, L2, L3, Neutral)  Class 1 accuracy
 100 and 400 V input
 Frequency measurement
 Field rotation detection
Power Sensing
 Class 1 accuracy
 Real and reactive power

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PAGE 7
Alarm Classes
Classes are free configurable for most monitoring functions
Class Action Result

Display Warning

Display and Horn Warning

Display and Horn Unload Gen. and open GCB Cool down Shut down

Display and Horn Immediately Open GCB Cool down Shut down

Display and Horn Unload Gen. and open GCB Immediate Stop Shut down

Display and Horn Immediately Open GCB Immediate Stop Shut down

For control purposes via LogicsManager to change/modify

sequencing or discrete outputs internal

8 |
Generator Protection
# of Trip Levels
 Over-/undervoltage
 Voltage asymmetry
 Over-/underfrequency
 Overload (IOP/MOP)
 Reverse/reduced power
 Unbalanced load
 Definite time-overcurrent
 Inverse time-overcurrent
 Overspeed (MPU)
 Measured ground current
 Calculated ground current
9 |
ANSI Code
2/2 [59/27]
1 [47]
2/2 [81O/U]
2 [32]
2 [32R/F]
2 [46]
3 [50/51]
1 [IEC 255]
2 [12]
2 [50G]
2
Generator Protection
# of Trip Levels ANSI Code
 Power factor (PF) lagging 2
 PF leading – loss of excitation 2
 Phase rotation field CW/CCW 1
 Unload mismatch (time out monitoring) 1 Controller*
 Operating range failed 1 Controller*

10 |
Engine Protection
 Maintenance days/hours exceeded
 Over-/Under speed (MPU)
 Unintended Stop
 Engine Stop malfunction
 Speed/frequency mismatch
 Start failure
 Charge alternator low voltage
 Red stop and Amber warning lamp (J1939)
 Battery over-/under voltage

11 |
Mains Protection
# of Trip Levels ANSI Code
 Over-/undervoltage 2/2 [59/27 ]
 Over-/underfrequency 2/2 [81O/U]
 Import/Export power 2 [32]
 Power factor leading 2
 Power factor lagging 2
 Phase shift 1ph/3ph [78 ]
 df/dt 1 [81R]
 Field rotation

12 |
Miscellaneous Monitoring
 Phase rotation mismatch generator / busbar / mains
 Mains decoupling
 CAN bus communications monitoring (J1939, CANopen)
 Parameter alignment (multiple units)
 Missing members (multiple units)
 Wire break analog inputs
 Discrete inputs
 Free Alarms (1-8)
 FlexLimitsTM for analog values
 Breaker Monitoring
 Breaker fail to open / close (GCB / MCB)
 Breaker Failure – 50BF (GCB / MCB)
 Sync time out (GCB / MCB)
 Neutral Contactor

13 |
 Neutral Interlocking
The Neutral Interlocking function controls in multiple-gen applications the Neutral
Contactor (NC) of each generator. The contactor bridges the Neutral with the PE. The
rule is that only one neutral of the running generators in the same segment are
bridged to earth.
The Logic ensures that with changing of generators or a lacking neutral breaker the
neutral link is passed over to another active running generator. This requires
information exchange between the genset controls. The load share protocol in the
easYgen provides the according information.

14 |
 Neutral Interlocking
Application

Wiring neutral Interlocking: GCB 3-pole Wiring neutral Interlocking: GCB 4-pole

15 |
 Neutral Interlocking
Start and operating
The genset control closes principally after each successful start (firing speed reached) the NC. The genset control proceeds
with closing the GCB, if the NC has been closed successfully. If the NC closure was not successful the easYgen issues an
alarm. The NC and GCB closure procedure is blocked from now on, until the alarm is acknowledged.
When the GCB is closed the genset control begins to figure out, whether the own NC can remain closed or must be opened.
This monitoring is done continuously. As long the GCB is closed, the NC remains closed or is closed, if:
 No connection to mains is active
AND
 one of the following is TRUE
– the own NC is the only closed NC in the same segment
OR
– there is minimum one other NC in the same segment closed but the own generator has a higher neutral interlocking priority
OR
– there is minimum one other NC in the same segment closed which has the same neutral interlocking priority but the
own genset control has a lower device number

In all other cases the NC is opened!

16 |
 Neutral Interlocking
Parameters in KG-1500
As long the engine/generator is running and the GCB is open the NC will be closed or remains closed until the engine
/ generator is stopped.

Neutral Interlocking ON/OFF

Neutral Closing Priority

The priority for closing GCB is configurable. This priority

is independent from the LDSS priority. The customer can
freely decide which generator shall get which priority.

17 |
 Neutral Interlocking
Parameters in KG-1500
The discrete input 10 (DI 10) is used as feedback of the Neutral contactor and cannot be configured
onto another discrete input. If the input is energized, the neutral contactor is recognized as closed..

Monitoring of NC feedback

The priority for closing GCB is configurable. This priority is independent from the LDSS priority. The
customer can freely decide which generator shall get which priority.

18 |
 Run-UP Sync
Close GCB before excitation

Transformer magnetizing: generator and transformer build up voltage gradually through the
start without large inrush

Fast magnetizing of multiple gensets (AMF, automatic mains failure)

Used to get several synchronous generators onto load in a very short time

Generators are paralleled by closing GCBs during engine start sequence

In some cases the in-rush current of a transformer may be more than one generator can supply
when closing the live generator to the dead transformer

19 |
 Run-UP Sync
General notes
RPM speed source required (MPU or J1939)

Only in isolated operation possible – Mains

connection will be opened!

The excitation can be simultaneous or individual.

The simultaneous excitation can reduce the cross
currents between generators in some critical
situations.

Mode GCB: While starting the engines the GCB

will be closed.

20 |
 Run-UP Sync
Application

A.Single generator with power

transformer.

B.Multiple generator with load on

common busbar.

C.Multiple generator with large

transformer on common busbar.

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 Run-UP Sync
Single generator with power transformer.

Precondition
 GCB open
GCB MCB  MCB open
 Engines stopped
 Run-up synchronization released (LM)

Load

22 |
 Run-UP Sync
Single generator with power transformer.

Application Flow
 Start Command
GCB MCB  Engine Started

Load

23 |
 Run-UP Sync
Single generator with power transformer.

Application Flow
 Start Command
GCB MCB  Engine Started
 GCB closed, when minimum
speed for close GCB is reached
(350 rpm)

Load

24 |
 Run-UP Sync
Single generator with power transformer.

Application Flow
 Excitation ON at 700 rpm (speed
GCB MCB for excitation to start)

Load

25 |
 Run-UP Sync
Multiple generators with load on common busbar
GCB
Precondition
 GCB open
 Engines stopped
 Run-up synchronization released (LM)
GCB Load

GCB

26 |
 Run-UP Sync
Multiple generators with load on common busbar
GCB
Application Flow
 Start Command
 Engines Started

GCB Load

GCB

27 |
 Run-UP Sync
Multiple generators with load on common busbar
GCB
Application Flow
 Start Command
 Engines Started
 GCB close, when minimum speed for
GCB Load
close GCB is reached (350 rpm)

GCB

28 |
 Run-UP Sync
Multiple generators with load on common busbar
GCB
Application Flow
 Excitation ON at 700 rpm (speed for
excitation to start)

GCB Load

GCB

29 |
 Run-UP Sync
Multiple generators with large transformer on common busbar
GCB
Precondition
 GCB open
 Engines stopped
 Run-up synchronization released (LM)
GCB Load

GCB

30 |
 Run-UP Sync
Multiple generators with large transformer on common busbar
GCB
Application Flow
 Start Command
 Engines Started

GCB Load

GCB

31 |
 Run-UP Sync
Multiple generators with large transformer on common busbar
GCB
Application Flow
 Start Command
 Engines Started
 GCB close, when minimum speed for
GCB Load
close GCB is reached (350 rpm)

GCB

32 |
 Run-UP Sync
Multiple generators with large transformer on common busbar
GCB
Application Flow
 Excitation ON at 700 rpm (speed for
excitation to start)

GCB Load

GCB

33 |
Configuration via ToolKit

RS-232 or CAN

34 |
Load setting file via KG1500 Setup s/w

RS-232

35 |
 Any Questions ?

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 ALWAYS INNOVATING FOR A BETTER FUTURE

37 | © WOODWARD, INC. PROPRIETARY