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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 Deep Sea Electronics Plc Highfield House Hunmanby North Yorkshire YO14 0PH ENGLAND Sales Tel: +44 (0) 1723 890099 Sales Fax: +44 (0) 1723 893303 E-mail: Sales@Deepseaplc.com © Deep Sea Electronics Plc All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means or other) without the written permission. Any reference to trademarked product names used within this publication is owned by their respective companies. Deep Sea Electronics Plc reserves the right to change the contents of this document without prior notice. Should you have any queries arising from this manual please contact our Technical Department: INTERNATIONAL TEL: +44 (0) 1723 890099 INTERNATIONAL FAX: +44 (0) 1723 893303 E-mail: support@deepseaplc.com Web: http://www.deepseaplc.com TABLE OF CONTENTS Section Page 41 INTRODUCTION 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 PART I & II · 5xxx configuration software manual · 5510 Operators Manual · 5520 Operators Manual · 5560 Operators Manual · Link5000plus Software Manual · Guide to Synchronising and Load Sharing PART I & II · P810 Software Manual · 550 Operators Manual · 555 Operators Manual · 556 Operators Manual · 557 Operators Manual · Link500plus Software Manual 2 Step by step guide This section details the main steps that need to be taken in producing your synchronising / load sharing system. This is intended as a guide only and is not a substitute for in depth knowledge of synchronising and load sharing. · Identify your base application. Applications supported by the DSE controllers are detailed in the section headed ‘Synchronising and load sharing solutions’. · Identify your governor and AVR interface methods. Details of this are contained in the Guide to Synchronising and Load Sharing Part2, under the headings ‘Interfacing to governors’ and ‘interfacing to Automatic voltage regulators’. · Design your panel and system wiring. DSE can assist with your specific questions on this but cannot design your panel for you. If you want a panel designing, please contact DSE Technical Support Department who may be able to recommend a third party panel designer / builder capable of producing a synchronising / load sharing system. · Check / adjust the DSE 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. NOTE: Highlights an essential element of a procedure to ensure correctness. CAUTION! Indicates a procedure or practice which, if not strictly observed, could result in damage or destruction of equipment. WARNING! Indicates a procedure or practice, which could result in injury to personnel or loss of life if not followed correctly. ã DEEP SEA ELECTRONICS PLC own the copyright to this manual, which cannot be copied, reproduced or disclosed to a third party without prior written permission. Compliant with BS EN 60950 Low Voltage Directive Compliant with BS EN 50081-2 EMC Directive Compliant with BS EN 50082-2 EMC Directive (( Year 2000 Compliant Two crossing wires with no interconnection between the two. Three wires, all connected together Connections to the 55x controller’s battery supply negative terminal, usually the earthed battery –ve terminal. A.V.R. Automatic Voltage Regulator. Fitted to the alternator to regulate the output of the generator. Governor Engine Speed Governor. Fitted to the engine to electronically control the speed of the engine. Droop When load is applied to a generator fitted with a droop governor / AVR, the speed/voltage will drop. This is called droop. It is common for a droop set to drop between 3% and 10% in speed / voltage from no load applied to full load applied. Isochronous A governor with no speed droop, or where speed droop is disabled is known as an isochronous governor. The engine speed remains constant so long as the load levels are within the set’s capability. Synchronise To get the supplies identically matched, ready for paralleling. Parallel Connect two or more supplies together. These supplies must be in synchronism before this can occur. Datum ‘centre’ point of an electronic pot, digital resistance or AVR/Governor. Nominal The nominal voltage or frequency of the system i.e. 230V 50Hz. This is not necessarily the same as the Datum. (i.e. when droop governors/AVRs are used, the datum will be higher than the nominal ) Mains supply The AC distributed power supply of a power generation company. 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 se