FG Wilson Product Training: 6000 Series Control System Malachy Roscoe 1/29/2021 6000 Series 1 Agenda •Basics and Terminology of Synchronisation •Load Control Methods •6000 Features •6000 Applications •The 6000 Series Controller •Reprogramming and Calibration •Communications Options 1/29/2021 6000 Series 2 Synchronisation Q. What do we mean by synchronisation? In terms of power generation, synchronisation is the matching of the output voltage waveform of one alternating current electrical generator with the voltage waveform of another alternating current electrical system. For two systems to be synchronised, five conditions must be matched: 1/29/2021 6000 Series 3 Synchronisation Q. What are the five conditions of synchronisation? •The number of phases in each system •The direction of rotation of these phases •The voltage amplitudes of the two systems •The frequencies of the two systems •The phase angle of the the voltage of the two systems 1/29/2021 6000 Series 4 Number of Phases The generating set of the oncoming system must have the same number of phases as those of the system it is to be paralleled: G 1/29/2021 L1 L1 L2 L2 L3 L3 6000 Series Mains or Generator 5 Phase Rotation Each generator or system being paralleled must be connected so that all phases rotate in the same direction. L1 L1 L2 L2 L3 L3 System 2 System 1 1/29/2021 6000 Series 6 Voltage Match The voltages generated by the systems being paralleled must be within a small percentage of one another, typically 1-5%. . AC 1 Volts AC 2 Time 1/29/2021 6000 Series 7 Voltage Match •If two systems of unequal voltage are paralleled, the difference in voltages result in reactive currents and lowered efficiency •If a generator is paralleled to the mains, a difference in voltage before paralleling will not change the voltage of the bus •In the above instance, if the generator voltage is much lower than the bus voltage the generator could be motorised. 1/29/2021 6000 Series 8 Frequency Match The voltages generated by the systems being paralleled must be within a small percentage of one another, typically 1-5%. . Volts AC 1 AC 2 Time 1/29/2021 6000 Series 9 Phase Angle Match The phase relationship between the voltages of the systems must be very close prior to paralleling. This match usually is within +/- 10 degrees. Volts AC 1 AC 2 Time 1/29/2021 6000 Series 10 Synchronisation Q. Why is synchronisation important? When two or more systems are paralleled to the same distribution system, the power sources must be synchronised properly. Without proper synchronisation of the oncoming system, power surges and mechanical or electrical stresses will result when the breaker is closed. 1/29/2021 6000 Series 11 Synchronisation Incorrect synchronisation under the worst conditions can lead to:•Voltage's being twice the rated voltage •One system can place a dead short on the other •High currents placing both systems under stress •Bent shafts and broken coupling discs •Power surges which build on each other until both systems are disabled 1/29/2021 6000 Series 12 Synchronisation Q. How is synchronisation accomplished? Normally, one generating system is used to establish the common bus and then the oncoming generator is then synchronised by changing the speed of the prime mover driver the oncoming generator. This can be done manually or automatically. 1/29/2021 6000 Series 13 Peak Load Control Peak Load Control refers to limiting the power purchased from the mains supplier. Electrical rates for large industrial users are usually calculated by the peak demand on the mains during a given time. Sometimes a peak demand lasting as brief as 15 minutes out of a 30 day period will determine the charge levelled for all the power purchased during that 30 day period. Peak Load Control can avoid over priced power bills by either: •Load Shedding as power levels reach the max defined level •Base loading •Peak Shaving 1/29/2021 6000 Series 14 Base-loading Base-loading is the operation of a generator at a constant output. When load demand exceeds the generator output capacity, power will be imported from the mains. If the base-loading exceeds the load demands, power may be exported to the mains grid. Power Demand Mains Supplied Load Generator Supplied Time 1/29/2021 6000 Series 15 Peak Shaving Peak shaving is used to set a limit on the maximum amount of power taken from the mains. The example below shows a maximum import from the mains as 100kW. Load Power Demand Generator Supplied 100kW Mains Supplied Time 1/29/2021 6000 Series 16 Import/Export Import Power and Export Power are terms used to describe power taken by the site load (import) or supplied to the mains grid (export) Load Power Demand Import Power Generator Capacity Site Demand Time 1/29/2021 6000 Series 17 Import/Export Import Power and Export Power are terms used to describe power taken by the site load (import) or supplied to the mains grid (export) Power Demand Load Generator Capacity Export Power Site Demand Time 1/29/2021 6000 Series 18 Zero Import (Export) Control A generator - or series of generators - is able to supply all the site power demand. This situation usually relies on generators to start and stop as demand fluctuates - Automatic Sequencing. Load Generator System Capacity Site Demand Generator Supplied Time 1/29/2021 6000 Series 19 Automatic Synchronisation A system that will automatically synchronise two systems it must have the able to: • Monitor the voltage and frequencies from both systems to be paralleled •Bias the voltage on the alternator and speed of the engine •Issue a breaker close command 1/29/2021 6000 Series 20 Automatic Synchronisation Bus Electronic Governor Engine Synchroniser Speed Bias Signal Close Breaker Signal Alternator Voltage Regulator Generator Voltage Breaker Typical Auto-Synch System Load 1/29/2021 6000 Series 21 6000 Series Controller •Automatic Synchroniser •Automatic Sequencing (up to 8 Generators) •Proportional Load Sharing (kW/kVAr) •4 Applications for Parallel/No Parallel and Single/Multiple •Engine & Generator Protections •Available in 12 Languages 1/29/2021 6000 Series 22 Language Options •English •German •Swedish •French •Danish •Italian •Finnish •Dutch •Icelandic •Portuguese •Norwegian •Spanish 1/29/2021 6000 Series 23 Engine Monitoring • Oil Pressure – Over/Under Alarm/Shutdown Settings • Water Temperature – Over/Under Alarm/Shutdown Settings • Battery Voltage – Over/Under Alarm/Shutdown Settings • Overspeed – Alarm/Shutdown Settings 1/29/2021 6000 Series 24 Auto-Start Function • Programmable Auto Start on Loss of Mains – All units in Auto mode with Loss of Mains detection enabled start and close onto load bus • Multiple Crank Repeat Setpoint • Crank Repeat Timer • Crank Fail Alarm/Shutdown • Crank Cutout (RPM) • Preglow 1/29/2021 6000 Series 25 Generator Monitoring • • • • • • 3 Phase Over/Under Voltage Over Current Reverse Power Loss of Excitation Over/Under Frequency Stable Generator Determined by Being within Voltage and Frequency Limits for a given period of time 1/29/2021 6000 Series 26 Mains Monitoring • • • • Over/Under Voltage Over/Under Frequency Load Surge Programmable for Alarm/Loss of Mains Detect – Loss of Mains Action Timer • Stable Mains determined by being within Voltage and Frequency Limits for a Given period of time 1/29/2021 6000 Series 27 Synchronising • Phase Match Synchronisation • 3 Mode Operation – run, check, permissive • Voltage Matching • Dead Bus Closing • Synch Timer • Reclose Attempt/Timer 1/29/2021 6000 Series 28 Load Control • • • • Proportional Load Sharing Integrating Base Load and Process Control Load Ramping Remote Contact Inputs to change Base Load and Process Setpoints with Raise/Lower ramp rates • Unload Trip point • Droop Load Control Capability 1/29/2021 6000 Series 29 Sequencing • Each Unit in the system has an assigned Priority • Master (Highest Priority) automatically sequences units on or off line as determined by system load. • Higher priority units are sequenced on in order of their priority; taken off in reverse of priority 1/29/2021 6000 Series 30 Sequencing • System Load setpoints determine percent system load level at which additional units will be brought on, or taken off line • Time setpoints determine period of delay for sequencing units on/off line • Separate time delay for overload (100%+) system load levels so additional units can be sequenced on line quickly 1/29/2021 6000 Series 31 Reactive Load Control • Var or Power Factor Load Control in Mains Parallel operation • Power Factor Sharing in Load Sharing, No Parallel operation • Externally adjustable VAR/PF reference • Manual Voltage Control Capability 1/29/2021 6000 Series 32 Mains Transfer Functions • Loss of Mains Action Timer • Fast Transfer Timer – Sets transfer time to/from Mains • Mains Stable Timer • Gen Stable Timer • Up to 8 generator system can re-synchronise across the mains tie on parallel transfer 1/29/2021 6000 Series 33 Controller Interface 1/29/2021 6000 Series 34 6000 Series Controller Max No. Units Genset Parallel Mains Parallel 6101 1 NO NO 6201 8 YES NO 6301 1 NO YES 6401 8 YES YES 1/29/2021 6000 Series 35 6000 Series Controller: 6100 • Single Unit No Parallel-6100 Mode (AMF) M M G LOAD 1/29/2021 6000 Series 36 6000 Series Controller: 6100 • Single Unit No Parallel-6100 Mode (AMF) • No Mains PT or Mains C.B. Aux Contact • Volt Free Start Signal • Load Transfer Functions and Mains Failure Detection Handled Externally • Open Load Transfer (External Changeover) • Isochronous Load Control • Dead Bus Closing 1/29/2021 6000 Series 37 6000 Series Controller • Typical 6000 Switch Configuration AUTO OFF 1/29/2021 TEST RUN 6000 Series 38 FG Wilson Schematic for 6000 Series Control Mode Switch 1/29/2021 6000 Series 39 6000 Series Controller: 6100 • Single Unit No Parallel-6100 Mode (AMF) • Auto – Unit waits for external start signal (AMF) • Test – Starts engine - if mains fails will power load • Run – Same as Test 1/29/2021 6000 Series 40 6000 Series Controller: 6100 • Single Unit Prime Power G LOAD 1/29/2021 6000 Series 41 6000 Series Controller: 6100 • Single Unit Prime Power • • • • No Mains PT Required No Mains Aux. Required Dead Bus Closing Isochronous Load Control 1/29/2021 6000 Series 42 6000 Series Controller: 6100 • Single Unit Prime Power • Auto – Starts Engine and Runs On Load • Test – Same as Auto • Run – Same as Auto and Test 1/29/2021 6000 Series 43 6000 Series Controller: 6200 • Multi Unit, No Parallel-6200 Mode (AMF) Up to 8 Generators G G G LOAD 1/29/2021 6000 Series 44 6000 Series Controller: 6200 • Multi Unit, No Parallel-6200 Mode (AMF) • • • • • Redundancy of Master Units No Mains PT or C.B. Aux Required Dead Bus Closing Isochronous Load Sharing Load Transfer Functions and LOM Detection handled externally • Load Dependant Auto Sequencing 1/29/2021 6000 Series 45 6000 Series Controller: 6200 • Multi Unit, No Parallel-6200 Mode (AMF) • Auto – Awaits Volt Free Start Signal – Enables Automatic Sequencing – Enables Dead Bus Closing • Test – Starts Engine; no further action • If Volt Free Start Signal received closes to bus • Run – Starts Unit, and Syncs to local bus or alternatively closes to dead bus 1/29/2021 6000 Series 46 FG Wilson Schematic for 6000 Series Control Mode Switch for Master 6200 1/29/2021 6000 Series 47 FG Wilson Schematic for 6000 Series Control Mode Switch for Master 6200 GST 1GSR 1/29/2021 1GTR 6000 Series 48 6000 Series Controller: 6200 When the changeover system senses that the mains has failed relays GSR (Gen Start Relay) will switch its contacts to give the 6000 an AUTO input and also a RUN input through GTR (Generator Timer Relay). This is so that Auto Sequencing will not be enabled for a timed period, GST. Once the time delay on GST (Gen Start Timer) has expired 1GTR will energise and switch its contacts removing the RUN input to the 6000, this means that Auto Sequencing will be enabled and generators will sequence ON/OFF line as required. 1/29/2021 6000 Series 49 6000 Series Controller: 6200 • Multiple Unit-6200 Mode (Prime Power) Up to 8 Generators G G LOAD 1/29/2021 6000 Series 50 6000 Series Controller: 6200 • Multiple Unit-6200 Mode (Prime Power) • • • • No Mains PT No Mains Aux. Dead Bus Closing Load Dependant Auto Sequencing 1/29/2021 6000 Series 51 6000 Series Controller: 6200 • Multiple Unit-6200 Mode (Prime Power) • Auto – Will Start the unit in Auto and it will close its gen breaker to the load – Enables Auto Sequencing – Enables Dead Bus Closing • Test – Same as Auto but engine always runs • Run – Starts Unit and allows unit to close gen breaker to the dead bus, or synchronize to a live bus if other generators are already on line. – Unit cannot be sequenced off-line 1/29/2021 6000 Series 52 6000 Series Controller: 6300 • Single Unit Parallel - 6300 Mode M M G LOAD 1/29/2021 6000 Series 53 6000 Series Controller: 6300 • Single Unit Parallel - 6300 Mode • Mains PT sensing • Mains C.B. Aux Contact • Auto input and software setpoints enable Loss Of Mains Detection • Isochronous Load Control on isolated bus • Dead Bus Closing • Soft Re-Transfer from generator to mains on Return of Mains 1/29/2021 6000 Series 54 6000 Series Controller: 6300 • Single Unit Parallel - 6300 Mode • Auto Position on Control Switch – Enables LOM Detection • Test Position on Control Switch – Starts Engine; no other action – LOM Detection Enabled • Run Position on Control Switch – Synchronises and Ramps to Base Load – LOM Detection Enabled 1/29/2021 6000 Series 55 6000 Series Controller: 6300 • Single Unit Parallel - 6300 Mode • Process Switch – When individually selected • No Action • Process Switch ON and Run on Control Switch – Synchronises and Ramps to Process Reference with LOM detection Enabled 1/29/2021 6000 Series 56 6000 Series Controller: 6300 • Single Unit Parallel - 6300 Mode • Process Switch OFF and Run on Control Switch – Synchronises and Ramps to Base Load – If “Load Control Mode” is set for Soft Transfer in configuration menu, unit will open mains breaker when base load reference is reached. 1/29/2021 6000 Series 57 6000 Series Controller: 6300 • Single Unit Parallel - 6300 Mode • Process Switch ON and Run on Control Switch – Synchronises and Ramps to Process Reference – Will open mains breaker/contactor upon reaching Process Reference if “Load Control Mode” setpoint in configuration menu is set for Soft Transfer. 1/29/2021 6000 Series 58 6000 Series Controller: 6400 • Multiple Unit, Mains Parallel (6400 Mode) M External PLC ControlLogic G M M M G LOAD 1/29/2021 6000 Series 59 6000 Series Controller: 6400 • Multiple Unit, Mains Parallel (6400 Mode) • • • • • • • Redundancy of Masters Mains C.B. Aux to all units (through PLC control) Mains PT input to all units (through PLC control) Loss of Mains Detection (through PLC control) Dead Bus Closing Isochronous Load Sharing when Isolated from Mains Base Load, Process, or Soft Transfer Control while in parallel with mains • Load Dependant Auto Sequencing in Load Sharing or Process Control 1/29/2021 6000 Series 60 Controller Interface • Two 16 character, 4 line back lit LCD displays with adjustable contrast • Large Keys with tactile feedback • Alarm/Shutdown LED indicator • Operator Input Keys (up, down, commit, escape, etc.) maintain common functions throughout all controller displays and modes. 1/29/2021 6000 Series 61 Hardware • 12 or 24 VDC supply voltage • 10 Amp /125 VAC (6 Amp 277 VAC) Relays • Isolated Power Supply • +/- 3VDC Speed Bias Output • +/-1, 3 or 9 VDC Voltage Bias Output 1/29/2021 6000 Series 62 Hardware • RS-422 PC interface network – Multi Drop, Multi Unit access from PC • RS-485 Load Sharing network – Intercontrol communications • 4 Control inputs determining operating mode – Auto, Test, Run and Process 1/29/2021 6000 Series 63 Keypad Detail • Vertical Keys AlarmReset Resets Alarms Clears Alarm Ind. 1/29/2021 Commit Enters Setpoints Enters Menus Commits Faults 6000 Series Escape Escapes Setpoints Escapes Menus 64 Keypad Detail • Horizontal Keys Up Key Down Key Moves Cursor Moves Cursor Increments Val. Decrements Val. 1/29/2021 Left Key Right Key Moves Cursor Moves Cursor 6000 Series 65 Keypad Detail • Right Hand Double Action Keys Upper Key Selects Status Menu Two Presses Selects Control Overview Screen (From any Menu) Lower Key Selects Tuning Menu Selects Setpoint Entry 1/29/2021 6000 Series 66 Screen Detail Top six lines (blue section) - Status Display Bottom two lines (white section) - Tunables Display 1/29/2021 6000 Series 67 Status Menus • Status Menus CONTROL OVERVIEW ENGINE OVERVIEW GEN OVERVIEW GEN PHASES SYNCHROSCOPE ALARM/EVENT LOG 1/29/2021 6000 Series 68 Status Menus • Status Menus (continued) I/O STATUS SEQUENCING -Accessed by pressing the down arrow to scroll down through status menu screen. 1/29/2021 6000 Series 69 Status Menus • Control Overview Engine off Line UNIT: 1 ENGINE: OFF MAINS: AUTO ALARMS: 0 GEN: OFF UNIT: 1 PRIORITY: 1 1/29/2021 6000 Series 70 Status Menus • Engine On Line on Isolated Bus UNIT: 1 ENGINE: RUN MAINS: AUTO ALARMS: 0 GEN: ISOCH UNIT: 1 PRIORITY: 1 1/29/2021 6000 Series 71 Status Menus • Engine Base Loaded To Mains UNIT: 1 ENGINE: RUN MAINS: AUTO ALARMS: 0 GEN: BASELOAD UNIT: 1 PRIORITY: 1 1/29/2021 6000 Series 72 Status Menus • Multiple Unit Control Overview Screen UNIT: 1 ENGINE: RUN MAINS: AUTO ALARMS: 0 GEN: BASELOAD UNIT: 12345 PRIORITY: 1 2 4 3 5 1/29/2021 6000 Series 73 Status Menus • Engine Overview H2O XXC TIME 12:00 OIL XXb DATE DD-MM KW-HRS 0 BATT XX.XV RPM 0 RUN TIME 0 1996 1/29/2021 6000 Series 74 Status Menus • Engine Overview – To set the time and date in the engine overview menu, supervisor password clearance (2nd level), is required. If this password is used, then the commit key on the 6000 control can be used to access the time and date display. The displayed time and date are then changed using the up/down and left/right arrows on the 6000. Pressing the commit key saves these values. 1/29/2021 6000 Series 75 Status Menus • Gen Overview (Voltage Line to Line) #1 A V 0.00 A 0.0 Hz: 00.0 B 0.00 0.0 C 0.00 0.0 KW: 00.0 PF: 1.00 LAGGING (LOAD CONT. STATUS) 1/29/2021 6000 Series 76 Status Menus • Gen Phases (Voltage Line to Neutral) 1 A V 0.00 A 0.0 KW0.00 B 0.00 0.0 0.00 C 0.00 0.0 0.00 kvar 0.0 kva 0.0 0.0 0.0 0.0 0.0 1/29/2021 6000 Series 77 Status Menus • Synchroscope Slip Phase **** **** Mains/Bus: Mains Dead Bus: Yes (SYNCHRONIZER STATUS) A: 0.0 1/29/2021 6000 Series Volts **** U: 0.0 78 Status Menus • Alarm/Event Log Unack Faults: 0 Faults Listing: None Recorded 1/29/2021 6000 Series 79 Status Menus • Alarm/Event Log Unack Faults: 2 Faults Listing: OVERSPEED 3-26 11:15 1700 LOW OIL PRESSURE 3-26 11:14 30 1/29/2021 6000 Series 80 Status Menus • Alarm/Event Log – Records and Logs Shutdown/Alarm events in chronological order. Most recent alarms appear at the top of the screen, with “oldest” alarms towards the bottom of the list. – Requires Operator (1st level) security to acknowledge alarms. – Use up/down arrows to scroll through multiple alarm log. 1/29/2021 6000 Series 81 Status Menus • Alarm/Event Log – Supervisor (2nd Level) Security Code required to clear alarms from Log – Committing alarm/shutdown will save the alarm in the Log and allow unit to operate – Clearing alarm/shutdown will remove the alarm from the Log and allow the unit to operate 1/29/2021 6000 Series 82 Status Menus • I/O Status (X Indicates Active input/output) DI: 1 2 3 4 5 6 7 8 9 0 1 2 X X DO: 1 2 3 4 5 6 7 8 9 0 1 2 X X Volt Bias: Speed Bias: 1/29/2021 0 0 6000 Series 83 1/29/2021 6000 Series 84 Discrete Inputs • • • • • • • 1- Automatic Switch 2- Test Switch 3- Run with Load Switch 4- Volts Raise 5- Volts Lower 6- Speed Raise 7- Speed Lower 1/29/2021 6000 Series 85 Discrete Inputs • • • • 8- Gen Circuit Breaker Aux Contact 9- Mains Circuit Breaker Aux Contact 10- Process Switch 11-12-13-14-15-16- Remote Alarm/Shutdown Inputs 1/29/2021 6000 Series 86 Discrete Outputs • • • • • 1- Mains Breaker Close/Contactor Close 2- Gen. Breaker/Contactor Close 3- Engine Preglow 4- Fuel Solenoid 5- Engine Crank • 6- Visual Alarm Relay 1/29/2021 6000 Series 87 Discrete Outputs • • • • 7- Local Bus PT Connect 8- Mains PT Disconnect 9- Mains Breaker Trip 10- Gen Breaker Trip • 11- Audible Alarm 1/29/2021 6000 Series 88 Status Menus • Sequencing Menu Unit: 1 Oper: Prty: 1 Master Unit: 1 Next On: All Next Off: 1/29/2021 6000 Series 89 Status Menus • Sequencing Menu (Multi-Unit) Unit: 1 2 3 4 5 6 7 8 Oper: X X X Prty: 1 4 2 7 3 5 8 6 Master Unit: 1 Next On: Next Off: 1/29/2021 2 5 6000 Series 90 Program • • • • Setpoints for Single/Multiple operation Parallel or No Parallel setpoints Multiple Level Security Codes Real Load Sharing, Soft Transfer, Base Load and Process Control Functions • Reactive Load Sharing and Var/PF Control 1/29/2021 6000 Series 91 Configuration Menus • Security Code Required For Access • All Items in Configuration Menu must be Committed before engine operation will be allowed. Uncommitted items will have an asterisk (*) next to them on the screen. • All Generator Parameters must be within ranges as defined by the following: – PT and CT ratios – Voltage Reference 1/29/2021 6000 Series 92 Configuration Menus • Security Code – 4 Levels Of Access • Operator (8448) – Access to Alarm Log and Network Priority • Supervisor (3494) – Allows access to Network Address and Time Set in addition to above access. • Technician (9251) – Allows access to all setpoints except calibration • Factory (****) – Allows access to all setpoints 1/29/2021 6000 Series 93 Configuration Menus There are 8 menus that may be accessed (dependant on Password): •Configuration •Shutdowns and Alarms •Engine Control •Synchroscope •Real Load Control •Reactive Load Control •Process Control •Calibration Menu 1/29/2021 6000 Series 94 Configure Menu • Network Address (1 to 8) – Unique Address for Each Unit in the System • Maximum of 8 units on network • Network Priority (1 to 8) – Unique Priority for Each Unit in the System • Lowest Active Priority is considered Master • Maximum of 8 units on network • Sequencing effective from lowest to highest priority 1/29/2021 6000 Series 95 Configure Menu • Number of Poles (numeric) – Determines Speed/Frequency Relationship • Used for Speed/Frequency Mismatch Alarm/Shutdown • Number of Teeth (numeric) – Determines RPM Scaling • Engine Speed Readouts/Alarms 1/29/2021 6000 Series 96 Configure Menu • System Frequency (50/60 Hz.) – Used as a basis for generator waveform analysis – Defines typical operating frequency of generator 1/29/2021 6000 Series 97 Configure Menu • Rated Speed (numeric) – Synchronous Speed Of Generator Set – Used in Speed Calculation to determine “sample” period for MPU input – Speed Governor sets this operating point on the engine 1/29/2021 6000 Series 98 Configure Menu • Rated KW (numeric) – Rated KW of Generator • Rated KVA (numeric) – Used to determine Rated Current of Generator • Equation: I=KVA/Rated Voltage 1/29/2021 6000 Series 99 Configure Menu • Rated KVAR (numeric) – Rated KVAR of Unit • Typically 0.6 x Rated KVA 1/29/2021 6000 Series 100 Configure Menu • Rated KVA must be less than or equal to the Voltage Reference x CT Ratio Primary • Rated KW must be less than or equal to the Rated KVA • Rated KVAR must be less than or equal to the Rated KVA • Any Values Falling out side of these ranges will appear on the screen with a pound sign (#) next to them. This indicates the value is out of range, and the engine will not operate until the # symbol is cleared by entering the correct values. 1/29/2021 6000 Series 101 Configure Menu • AC Power Triangle KVA KVAR KW 1/29/2021 6000 Series 102 Configure Menu • CT Ratio (numeric :5) – Scales sensed CT input for Amperage as seen at generator – Used for Load Sensing Algorithm • (KVA,KW,KVAR,PF) – Used for Alarms/Shutdowns • Over Current, KW Limits,Reverse Current, etc. 1/29/2021 6000 Series 103 Configure Menu • PT Ratio (numeric : 1) – Scales sensed PT input to Voltage Levels as measured at the Generator – Used in Load Sensing Algorithm • (KVA, KW, KVAR, PF) – Used for Voltage Matching – Used for Generator Frequency Detection – Used for Alarm/Shutdown sensing • Over/Under Frequency • Over/Under Voltage • KW Limits, etc. 1/29/2021 6000 Series 104 Configure Menu • 6000 Potential Transformer 320V •Voltage into primary winding must never exceed tapping rating 250V 50Vrms 130V 64V 0V Primary Secondary 1/29/2021 •Use caution if reconnecting alternator winding and ensure that the PT Ratio settings reflect the tapping point used on transformers 6000 Series 105 Configure Menu • PT Ratio 250:50 G 380/220 VAC 1/29/2021 6000 PT Ratio = 5:1 50 VAC 6000 Series 106 Configure Menu • Voltage Input (Wye L-N, Delta L-L) – Set for sensing/transformer used between generator and Gen Part 6000. – Defines which calculations will be used for KW, KVA, KVAR, etc. 1/29/2021 6000 Series 107 Configure Menu • Wye (Star) Generator or Transformer Connection – 4 Wire – Volts Line to Neutral • Delta Generator or Transformer Connection – 3 Wire – Volts Line to Line 1/29/2021 6000 Series 108 Configure Menu • 3 phase True RMS sensing of Voltages and Currents • Delta or Wye (Star) PT inputs • 4 wire CT input • Configurable for a wide range of 50/60 Hz. systems up to 30 MW per unit. • Distortion/Harmonic filtering for accuracy 1/29/2021 6000 Series 109 Configure Menu • Voltage Reference (numeric) – Operating Voltage of Generator per Generator Spec. – Used for Var/PF Sharing as the Reference that multiple generators share reactive load to. This maintains the voltage reference while in Power Factor Sharing mode on an isolated bus. 1/29/2021 6000 Series 110 Configure Menu • Load Control Mode – Normal • Standard setting for load control and VAR/PF functions – Soft Transfer • Standard load control and VAR/PF functions, but unit will issue mains breaker open command while in process control if process reference is reached, or while in base load and base load reference is reached. – Droop • Manual Load and Voltage Control • Used primarily for commissioning 1/29/2021 6000 Series 111 Configure Menu • Process Action (direct, indirect) – Defines action of speed bias when unit is operating in process control in parallel with the mains. • Direct action = Unit increases speed bias (fuel) to increase process 4- 20 ma input • Indirect action = Unit decreases speed bias (fuel) to increase process 4-20 ma input. 1/29/2021 6000 Series 112 Configure Menu • Process Import/Export Hardware – 6000 Control Can take a 4-20 mA, or 1-5 VDC input signal from a transducer. Input signal conditioning is selected by a dip switch on the back of the control 8 7 6 5 4 3 2 1 Switch 8 ON for 4-20 mA input. OFF for 1-5 VDC input SW-2 1/29/2021 6000 Series 113 Configure Menu • Circuit Breaker Control (Breaker/Contactor) – Defines action of Generator and Mains closure command • Breaker issues momentary close signal, momentary open signal independently. • Contactor issues continuous close signal. Removes this signal to open contactor. 1/29/2021 6000 Series 114 Configure Menu • Check Mains Breaker (enabled/disabled) – Used to activate checking of mains c.b. aux. input when enabled – If disabled, unit relies on other units with this setpoint enabled to broadcast state of mains c.b. aux. contact over network 1/29/2021 6000 Series 115 Configure Menu • Operating Mode – Mains Parallel or No Parallel • Mains Parallel will allow the unit to synchronise to the mains, and carry load while in parallel with the mains as well. • No Parallel will not allow the unit to operate with load until the mains breaker is sensed as being open • All units operating in a load sharing system must be set for the same parameter, i.e. mains parallel, or no parallel. 1/29/2021 6000 Series 116 Configure Menu • Number of Units (single, multiple) – Defines whether unit is part of a mulitple unit system or not. • If single unit, there is no auto starting, auto sequencing,load or pf sharing with other units under any circumstances. Unit displays “single unit no sequencing” on sequencing screen. • If multiple unit, auto starting, auto sequencing, load and var/pf sharing are active between all units in multiple. Unit displays system sequencing information on sequencing screen. 1/29/2021 6000 Series 117 Configure Menu • Automatic Mode (enabled/disabled) – Enables or Disables Auto Sequencing for that unit – Can be used to disable sequencing for a particular unit in a sequencing system if needed 1/29/2021 6000 Series 118 Configure Menu • 422 Protocol (Modbus, Servlink, Upload Setpoints) – Allows selection of how the 422 Protocol will be used. • Modbus is selected when the industry standard protocol ModBus is required to be utilised, controller must be re-booted if this option is selected • Servlink is selected when operating with PC Tools, controller must be re-booted if this option is selected • Upload Setpoints is selected when an electronic copy of the configuration file is required and should only be used by FG Wilson personnel 1/29/2021 6000 Series 119 Shutdowns & Alarm Menu • Shutdowns and Alarms menu is used to configure the various safety functions of the Gen Part 6000. 1/29/2021 6000 Series 120 Shutdowns & Alarm Menu • Each alarm setpoint can be set for : – Disabled – Warning • LED on Control Flashes – Visual Alarm • LED Flashes, and Visual Alarm relay energises – Audible Alarm • LED Flashes, Visual and Audible Alarm relays energise 1/29/2021 6000 Series 121 Shutdowns & Alarm Menu – Soft Shutdown • LED Turns On, Visual and Audible Alarm relays energise, Unit soft unloads and cycles through cool down timer when applicable. – Hard Shutdown • Same as above, but immediately opens generator breaker and de-energises fuel solenoid 1/29/2021 6000 Series 122 Shutdowns & Alarm Menu • Loss of Mains /Loss of Mains w/Alarms – Additional alarm setpoint used in the following: • Mains over/under voltage • Mains over/under Frequency • Load Surge 1/29/2021 6000 Series 123 Shutdowns & Alarm Menu • Load Surge (numeric %/sec) – Used only in Base Load or Process Control (Mains Parallel Operations) – Set to trigger at a percent setpoint of total generator load shift per second while operating in Mains Parallel – Can be set for Loss of Mains Detection – Instantaneous Trigger 1/29/2021 6000 Series 124 Shutdowns & Alarm Menu • Main Volt High Limit (numeric) – Alarms when Mains Voltage exceeds Alarm Setpoint. • Alarm can be set for Loss of Mains – If Mains Voltage is above High Limit, Mains are not considered stable, and the 6000 control will not issue a mains breaker closure command. 1/29/2021 6000 Series 125 Shutdowns & Alarm Menu • Mains Volt Low Limit (numeric) – Alarms when Mains Voltage drops below setpoint • Alarm can be set for Loss of Mains – If Mains Voltage is below Low Limit, Mains are not considered stable, and the 6000 control will not issue a mains breaker closure command. 1/29/2021 6000 Series 126 Shutdowns & Alarm Menu • Main Freq. High Limit (numeric) – Alarms when Mains Frequency exceeds Alarm Setpoint. • Alarm can be set for Loss of Mains – If Mains Frequency is above High Limit, Mains are not considered stable, and the 6000 control will not issue a mains breaker closure command. 1/29/2021 6000 Series 127 Shutdowns & Alarm Menu • Mains Freq. Low Limit (numeric) – Alarms when Mains Frequency drops below setpoint • Alarm can be set for Loss of Mains – If Mains Frequency is below Low Limit, Mains are not considered stable, and the 6000 control will not issue a mains breaker closure command. 1/29/2021 6000 Series 128 Shutdowns & Alarm Menu • LOM Action Delay (numeric seconds) – Sets Time Delay for LOM Action to begin once Loss of Mains is detected. • Typically Delay time From LOM to engine start command 1/29/2021 6000 Series 129 Shutdowns & Alarm Menu • Voltage Range Alarm (enabled, disabled) – Alarm/Shutdown point for an excess of voltage bias signal from the GCP to AVR – Preset to trigger at +/- 100% voltage bias output. 1/29/2021 6000 Series 130 Shutdowns & Alarm Menu • Generator high/low voltage alarms Operating Range Generator High Voltage Limit (Voltage Bias Cutout) Rated Generator Voltage Generator Low Voltage Limit (Voltage Bias Cutout) 1/29/2021 6000 Series 131 Shutdowns & Alarm Menu • Gen Volt High Limit (numeric) – Sets maximum allowable generator voltage level • If voltage is above High Limit, generator is not considered stable, and is unfit for breaker closure. • Gen Volt Low Limit (numeric) – Sets minimum allowable generator voltage level • If voltage is below Low Limit, generator is not considered stable, and is unfit for breaker closure 1/29/2021 6000 Series 132 Shutdowns & Alarm Menu • Generator High/Low Volt Limits – Even if the Alarm Setpoints for the High/Low Limits are Disabled, the Voltage Bias will not allow adjustment beyond these limits. – The same is true for the synchroniser, which will not allow a gen breaker closure if the High or Low Voltage limits are met or exceeded. 1/29/2021 6000 Series 133 Shutdowns & Alarm Menu • Generator Freq High Limit (numeric) – Sets maximum allowable generator frequency level • If frequency is above High Limit, generator is not considered stable, and is unfit for breaker closure. • Generator Freq Low Limit (numeric) – Sets minimum allowable generator frequency level • If frequency is below Low Limit, generator is not considered stable, and is unfit for breaker closure 1/29/2021 6000 Series 134 Shutdowns & Alarm Menu Opegrating Range • Generator Over/Under Frequency Generator High Frequency Limit (Speed Bias Cutout) Synchronous Speed (50/60 Hz) Generator Low Frequency Limit (Speed Bias Cutout) 1/29/2021 6000 Series 135 Shutdowns & Alarm Menu • Generator High/Low Freq. Limits – Even if the Alarm Setpoints for the High/Low Limits are Disabled, the Speed Bias will not allow adjustment beyond these limits. – The same is true for the synchronizer, which will not allow a gen breaker closure if the High or Low Frequency limits are met or exceeded. 1/29/2021 6000 Series 136 Shutdowns & Alarm Menu • Spd/Freq Mismatch (enabled/disabled) – Compares generator frequency to engine RPM and alarms on difference – Used to indicate loss of MPU, or Loss of Generator Field Voltage 1/29/2021 6000 Series 137 Shutdowns & Alarm Menu • Overspeed (numeric) – Set for overspeed limit of engine • Typically set for Hard Shutdown for safety – Typically Set for 10% above Rated Speed of engine 1/29/2021 6000 Series 138 Shutdowns & Alarm Menu • Over Current Level (numeric) – 3 Phase Sensing – Set for Per Phase Overcurrent – Over Current Detection begins when current exceeds rated current as determined by Voltage Reference and Rated KVA values in Configuration menu – Uses Inverse Time Function as basis for overcurrent detection. This allows different levels of overcurrent based on time span. 1/29/2021 6000 Series 139 Shutdowns & Alarm Menu • Overcurrent Inverse Time Function Per Phase amps Overcurrent Trip Zone overcurrent level 100% rated current overcurrent delay 1/29/2021 6000 Series time 140 Shutdowns & Alarm Menu • Over Current Level – High Current, Short Duration amps Overcurrent Trip Zone overcurrent level overcurrent delay 1/29/2021 6000 Series time 141 Shutdowns & Alarm Menu • Overcurrent Level – Notice area of over current is the same amps Overcurrent Trip Zone overcurrent level overcurrent delay 1/29/2021 6000 Series time 142 Shutdowns & Alarm Menu • Reverse Power Level (numeric) – Reverse Power Condition begins when sensed KW on generator goes negative. Reverse Power Trip levels depend upon amplitude and duration of reverse power condition. • Reverse Power Delay (numeric) – Reverse Power also uses an inverse time function. 1/29/2021 6000 Series 143 Shutdowns & Alarm Menu • Reverse Power KW + Reverse Power Delay 0 KW Reverse Power Time Reverse Power 1/29/2021 6000 Series 144 Shutdowns & Alarm Menu • Loss of Exictation (LOE) (numeric) – Set as a percentage of total KVAR load on the generator that can be applied as a block reactive load to the unit. If control senses changes in KVAR loads instantly applied greater than this value the LOE alarm triggers. – Used to indicate loss of field excitation to the generator 1/29/2021 6000 Series 145 Shutdowns & Alarm Menu • Battery Volt High Limit (numeric) – Sensed DC voltage supply to 6000 control – Can be used to detect faulty charging circuit • Battery Voltage Low Limit (numeric) – Used to detect weak battery/failed charger – Automatically Disabled during engine cranking 1/29/2021 6000 Series 146 Shutdowns & Alarm Menu • Approaching High H2O Temp. (numeric) – Uses engine mounted temp sensor – Active once Gen is considered stable – Sensed in degrees C • Low H2O Temp. (numeric) – Useful for detection of failed jacket water heater – Always Active 1/29/2021 6000 Series 147 Shutdowns & Alarm Menu • High Oil Pressure (numeric) – Uses Engine mounted pressure sensor – Active when generator is stable – Sensed in Bar • Approaching Low Oil Pressure – Used to sense failure of lube oil system – Active when generator is stable 1/29/2021 6000 Series 148 Shutdowns & Alarm Menu • External Faults #1 through #6 – Each fault is programmable for: • • • • • • disabled warning visual alarm audible alarm soft shutdown hard shutdown 1/29/2021 6000 Series 149 Shutdowns & Alarm Menu • External Faults #1 and #2 – 15 second delay for activation after reaching crank cutout speed. – Used for oil pressure and water temp switch inputs • External Faults #3 through #6 – Instant action – Always active 1/29/2021 6000 Series 150 Engine Controls Menu • Preglow Time – Time of preglow allowed prior to engine crank cycle – Maintained through engine cranking – Resets after every crank attempt 1/29/2021 6000 Series 151 Engine Controls Menu • Crank Time – Maximum Allowable Time for Engine Cranking • Crank Cutout – Engine RPM level where crank command is canceled • Crank Delay – Time between Engine Crank Attempts 1/29/2021 6000 Series 152 Engine Controls Menu • Crank Repeats – Number of times 6000 control will attempt to re-start engine. Cranking attempts will equal the value of Crank Repeats +1. • Crank Fail – Alarm Setpoint • Activates when Number of Crank Repeats is depleted. 1/29/2021 6000 Series 153 Engine Controls Menu • Cooldown Time – Time allowed for cooldown once engine achieves a stop cycle – Must exceed Cooldown Limit (see next display) before activated 1/29/2021 6000 Series 154 Engine Controls Menu • Cooldown Limit – KVA setpoint at which, when exceeded, will cause the engine to go to a cooldown during a stop cycle 1/29/2021 6000 Series 155 Engine Controls Menu • Engine Run Time – Hours of Run Time on Engine • Increments in hours • Retained in EE memory - Does not require power to maintain previous value • MW Hours – MW Hours on Generator • Increments in .1 MWH • Retained in EE memory 1/29/2021 6000 Series 156 Synchroscope Menu • Synchronizer Mode – Permissive • Acts as a synch check device. • 6000 will not issue speed or voltage bias commands, but if synchronization conditions are within spec (phase and voltage), control will issue a breaker close command. 1/29/2021 6000 Series 157 Synchroscope Menu – Check • Used for checking synchronizer prior to commisioning • 6000 control actively synchronizes generator by issuing speed and voltage bias commands, but does not issue breaker closure command 1/29/2021 6000 Series 158 Synchroscope Menu – Run • Normal operating mode • Actively synchronizes and issues breaker closure command • 6000 control MUST be in RUN to operate as a dead bus closing device. • In multiple unit systems 6000 control MUST have AUTO input active to enable dead bus closing 1/29/2021 6000 Series 159 Synchroscope Menu • Synchronizer Gain – Sets Gain of Synchronizer speed bias output • Synchronizer Stability – Sets Stability of Synchronizer speed bias output – Both Gain and Stability are used to tune the synchronizer dynamic response. 1/29/2021 6000 Series 160 Synchroscope Menu • Gain and Stability – Gain (Output/Input) Phase Transient Low Gain Output High Gain Output 1/29/2021 6000 Series Too little gain: Sluggish Response with Large Overshoot Too much gain: Rapid cycling of engine speed 161 Synchroscope Menu • Gain and Stability – Stabililty (Integrator dx/dt) phase match line Large value Long return to phase match condition phase match line Small value Rapid return to phase match condition 1/29/2021 6000 Series 162 Synchroscope Menu • Voltage Matching (enabled or disabled) – Enables/Disables Voltage Matching feature of 6000 control • Enables VoltageWindow Setpoint • Voltage Window (numeric) – Overall percentage of error allowed between generator and bus, or generator and mains – 6000 control will not issue a breaker closure if error is greater than voltagewindow 1/29/2021 6000 Series 163 Synchroscope Menu • Voltage Matching (1% setpoint) Gen Voltage High Bus or Mains Voltage 381.9 VAC +0.5% 380 VAC 378.1 VAC - 0.5% Gen Voltage Low 1/29/2021 6000 Series 164 Synchroscope Menu • Max. Phase Window – Maximum allowable phase angle deviation from phase matched condition. – 6000 Control will not issue breaker closure if phase angle between generator and bus, or generator and mains exceeds this window 1/29/2021 6000 Series 165 Synchroscope Menu • Max. Phase Window =10 degrees -10 o +10 Must be within +/- 10 deg window for breaker closure 1/29/2021 6000 Series 166 Synchroscope Menu • Dwell Time (numeric) – The period of time that the generator must be within the Max. Phase Window for before the 6000 control will issue a breaker closure – Longer dwell times will give typically give better stability after the breaker closes – Shorter dwell times reduce amount of time required to synchronize unit 1/29/2021 6000 Series 167 Synchroscope Menu • C.B. Hold Time – Time in Seconds that Breaker/Contactor Close output is held after breaker close command is issued • Close Attempts – Number of Close Attempts allowed while synchronizing – Close attempt incremented if breaker does not send back continuous CB aux signal to 6000. 1/29/2021 6000 Series 168 Synchroscope Menu • Reclose Delay – Time in Seconds before 6000 control attempts resynchronization after failed closure attempt • Synch Reclose Alarm – Alarm setpoint if number of close attempts is depleted 1/29/2021 6000 Series 169 Synchroscope Menu • Synchronizer Time Out – Sets time allowed for synchronization in seconds – Begins timing when synchronizer activates – Active for all gen and mains breaker open/close commands from 6000 control – A setting of zero (0) seconds disables synch. timeout infinite synch time allowed • Synch Timeout Alarm – Sets alarm mode if sych timeout is exceeded 1/29/2021 6000 Series 170 Synchroscope Menu • Dead Bus Closure – Enables/Disables Dead Bus Closing Feature • Unit must be within voltage and frequency high/low limits to be considered for dead bus closure. • Dead Bus Closure uses Token Passing Scheme to assure that only one unit in a networked system will close onto the dead bus at any given time. • Mulitple unit systems must have Auto switch input to allow dead bus closing between networked units 1/29/2021 6000 Series 171 Real Load Control Menu • Load Control Gain – Sets gain response of load control • Active in load ramping and base load operations • Load Share Gain – Sets gain response of proportional load sharing • Active in load sharing operations 1/29/2021 6000 Series 172 Real Load Control Menu • Load Stability – Sets Stability response of load control • Active in load ramping and base load operations • Load Derivative – Sets Derivative response of load control • Active in load ramping and base load operations 1/29/2021 6000 Series 173 Real Load Control Menu • Load Control Filter – Low Pass Filter used to attenuate higher frequency transients for better stability • Active in proportional load sharing, load ramping, and base load control modes • Higher values of filter will tend to make the unit more responsive to small, rapid transients • Lower values of filter will tend to make the unit less responsive to small, rapid transients 1/29/2021 6000 Series 174 Real Load Control Menu • Base Load – Load Level Generator will automatically ramp to when operating in Base Load • Unload Trip – Load Level where Generator Breaker/Contactor open command will be issued when 6000 control is off loading generator set 1/29/2021 6000 Series 175 Real Load Control Menu • Load Droop – Percentage of KW droop used when 6000 control is operating in a droop mode • Load Time – Time in Seconds for generator to load from unload trip level to base load level. This rate is applied during any automatic loading function, including ramping to load sharing 1/29/2021 6000 Series 176 Real Load Control Menu • Unload Time – Time in Seconds for generator to unload from base load level to unload trip level. This ramp rate is applied during any automatic unload functions, including ramping from load sharing 1/29/2021 6000 Series 177 Real Load Control Menu • Raise Load Rate – Pecent Load per Second ramp rate used when the raise load contact input is used during base load operation. • Lower Load Rate – Percent per Second Ramp Rate used when the load lower input is active in base load control operation 1/29/2021 6000 Series 178 Real Load Control Menu • Gen. Load High Limit – Maximum allowed load while operating in Base load or Process control modes • Prevents overload of unit • Gen High Limit Alarm – Sets alarm mode when unit is at or above High Load Limit • Active during all load control operations 1/29/2021 6000 Series 179 Real Load Control Menu • Gen. Load Low Limit – Minimum allowed load while operating in Base load or Process control modes • Prevents reverse current of unit • Low Load Limit Alarm – Sets Alarm Mode when unit is at or below Low Load Limit • Active during all load control operations 1/29/2021 6000 Series 180 Real Load Control Menu • Fast Transfer Delay – Time required for a transition in switching from Mains to Generator operations, and from Generator to Mains operations. This includes transition times between bus and mains sensing. – Mains Stable Delay – Period of time required for the mains to be declared stable before transition from generator(s) to mains. 1/29/2021 6000 Series 181 Real Load Control Menu • Gen Stable Delay – Period of time generator must be declared stable before transition from Mains to Generator, as well as dead bus closing 1/29/2021 6000 Series 182 Real Load Control Menu • Next Genset Delay – Period of time that will pass before master auto sequences an additional generator on line. – Delay is effective only in active master unit 1/29/2021 6000 Series 183 Real Load Control Menu • Max. Gen Load – % system load on all units with gen breakers closed, and on the same network, in Auto,and in Load Sharing or Process control modes, at which active master unit will begin timing to sequence next unit on line. 1/29/2021 6000 Series 184 Real Load Control Menu • Rated Load Delay – Delay when system load exceeds 100%, before master starts next genset in sequence • Overload condition fast sequence operation • Rated Load Delay function overrides load ramping on unit being sequenced on line. That unit will immediately assume its proportion of the system load. 1/29/2021 6000 Series 185 Real Load Control Menu • Max. Start Time – Time allowed by master to see next unit to be sequenced on line in an “active” condition, i.e. started and ready to load. – This is determined by a flag, which indicates the unit is ready to load, is sent over the network by the unit being sequenced on by the master. – If master does not detect this flag within the Max. Start Time allowed, it will go to the next lower priority unit and try starting it, or if no other units are available, it will retry the command on the same unit. 1/29/2021 6000 Series 186 Real Load Control Menu • Reduced Load Delay – Time in seconds which the active master waits before sequencing units off line. – Delay is effective only on active master unit – Lowest priority units are sequenced off line first 1/29/2021 6000 Series 187 Real Load Control Menu • Min. Gen. Load – % of system load at which active master begins timingto sequence units off line – Master may have to wait until system load is below this level if unit next in line to be sequenced off will cause the system load to increase above the Max Gen Load setpoint of the Master. 1/29/2021 6000 Series 188 Real Load Control Menu • Max. Stop Time – Time in seconds allowed by master for slave to sequence off line – Master begins sequencing next lowest priority unit off line if system load is still above Min. Gen. Load setpoint at the end of the Max Stop Time Limit 1/29/2021 6000 Series 189 Reactive Load Control Menu • Var/PF Mode – Disabled • Unit does not PF share, or control PF under any circumstances – VAR Control • Unit PF shares in isolated bus load sharing mode • Unit controls KVAR in Base Load and Process Control Modes – PF Control • Unit PF shares in isolated bus load sharing mode • Unit controls PF in Base Load and Process Control Modes 1/29/2021 6000 Series 190 Reactive Load Control Menu • Var/PF Gain – Controls Gain Response of unit in Var/PF control mode • NOT active in PF sharing mode • Var/PF Share Gain – Not Active in any modes • Var/PF Stability – Controls Stability Response of unit in Var/PF control mode – NOT active in PF sharing mode 1/29/2021 6000 Series 191 Reactive Load Control Menu • Voltage Ramp Time – Ramp time from 0 to +/-100% voltage bias output • Controls response of units in PF sharing modes • Controls ramp time of voltage during synchronization • Controls ramp time of voltage during manual voltage adjust 1/29/2021 6000 Series 192 Reactive Load Control Menu • KVAR Reference – When KVAR control mode is selected, this references the amount of KVAR the generator will produce while in Base Load or Process control modes – Can be set for generate or absorb levels of KVAR • KVAR levels limited by Rated KVAR of unit 1/29/2021 6000 Series 193 Reactive Load Control Menu • PF Reference – PF level that will be maintained by the generator while in Base Load or Process control modes. • Can be set for leading or lagging power factor • Scaled from 0 (unity) to -.5 (.5 leading) to +.5 (.5 lagging) 1/29/2021 6000 Series 194 Reactive Load Control Menu • PF Deadband – +/- deadband around PF reference point • set in PF • Active in PF and PF sharing modes • Can be used to stabilise units at low loads if needed 1/29/2021 6000 Series 195 Process Control Menu • Process Dynamics – Process Master Uses Process PID to control • Gain, Stability, Derivate, Filter, Droop – Slaves to the Process Master use Load Control PID Values to track master system load reference • Load Gain, Stability, Derivate, Filter 1/29/2021 6000 Series 196 Process Control Menu • Process Gain – Sets system gain response while in process control • Effective at active master unit only. Slaves rely on Load Control dynamic settings to control response to master load reference • Should be set with maximum number of units operating in process control mode 1/29/2021 6000 Series 197 Process Control Menu • Process Stability – Sets system stability response while in process control • Effective at active master unit only. Slaves rely on Load Control dynamic settings to control response to master load reference • Should be set with maximum number of units operating in process control mode 1/29/2021 6000 Series 198 Process Control Menu • Process Derivative – Sets system derivative response while in process control • Effective at active master unit only. Slaves rely on Load Control dynamic settings to control response to master load reference • Should be set with maximum number of units operating in process control mode 1/29/2021 6000 Series 199 Process Control Menu • Process Droop – Introduces negative feedback on the process reference as the process input increases – Used to add stability to marginally stable processes 1/29/2021 6000 Series 200 Process Control Menu • Process Filter – Low Pass Filter attenuates higher frequency transients on process 4-20 mA input signal – The higher the filter is set, the more active the process control will be to higher frequency process transients – The lower the filter is set, the less active, and more stable the process control will be to higher frequency process transients 1/29/2021 6000 Series 201 Process Control Menu • Process Reference – The reference point, in mA, at which the master will control the process input. – Also used in Soft Transfer modes to set the level of process at which the transfer from mains to generator will occur 1/29/2021 6000 Series 202 Process Control Menu • Raise Rate – Rate, in mA/Sec., at which the process reference will change when the 6000 control receives a raise load contact input while operating in process control mode 1/29/2021 6000 Series 203 Process Control Menu • Lower Rate – Rate, in mA/Sec., at which the process reference will change when the 6000 control receives a lower load contact input while operating in process control mode 1/29/2021 6000 Series 204 Process Control Menu • Process High Limit – Maximum allowable process reference level. Set in mA – Effective on active master unit only • Process High Limit Alarm – Sets alarm mode when process High Limit is reached 1/29/2021 6000 Series 205 Process Control Menu • Process Low Limit – Maximum allowable process reference level. Set in mA – Effective on active master unit only • Process Low Limit Alarm – Sets alarm mode when process reference reaches the Low Limit 1/29/2021 6000 Series 206 Calibration Menu • While each unit will be factory calibrated at FG Wilson prior to shipment, there are bound to be some inputs/outputs affected by external wiring and/or interfaces (relays, transformers, etc..) that will require calibration at the site during commissioning. • The Calibration Menu allows calibration of all the analog inputs to the 6000 control, as well as the speed bias and voltage bias outputs. 1/29/2021 6000 Series 207 Calibration Menu • All calibration points in the 6000 control are used to make the actual value of an input, such as generator voltage, read out on the respective display screen of the 6000 control the proper value of the signal being monitored. • Example: 380VAC measured line to line on the generator should read 380VAC in the line to line voltage measurement area of the 6000 control “generator overview” menu. • Any differences between the measured and actual values can be corrected using the generator PT calibration points in the calibration menu. 1/29/2021 6000 Series 208 Calibration Menu • Process input Scale – Actual Input - 4-20 mA, or 1- 5VDC process signal from external transducer. – Monitor the Pin (process in) reading in the Load Control Monitor menu – Calibrate Process input scale until Pin reads accurately what measured process signal is. – Engine must be in a test or run mode and operating to observe the Pin value in the Load Control Monitor menu 1/29/2021 6000 Series 209 Calibration Menu • Measured vs Monitored 380.2 VAC Measured L-L Monitored Volts L-L in Gen Control Overview A B C 380.2 380.2 PT phase A scale 2.356 Calibrate monitored to equal measured in Calibration menu. G 1/29/2021 6000 Series 210 Calibration Menu • Speed Bias Offset – Factory calibrated for 0VDC offset on +/- 3 VDC range. – All Woodward Speed controls operate with this bias output, so no calibration should be required – Calibration may be required for other manufacturer’s speed controls... 1/29/2021 6000 Series 211 Calibration Menu • Voltage Bias Offset – Factory set for zero Volts DC. – Dip Switch selectable +/- 1VDC, +/- 3 VDC, +/- 9 VDC range. – Some regulators require a positive voltage bias offset because they cannot recieve a negative voltage bias command. – 6000 control will always reset to the voltage bias offset when off line. 1/29/2021 6000 Series 212 Calibration Menu • Typical AVR with Aux input +/- 1 VDC input from 6000 trim Trim Adj. Volts 1/29/2021 Internal Trim adjustment potentiometer sets effective range of +/- 1 VDC bias from 6000 control. Usually a +/- 10% voltage change for the +/-1VDC input is more than sufficient for good VAR and PF control. 6000 Series 213 Calibration Menu • Typical AVR with external Voltage adjust Potentiometer +/- VDC input from 6000 Volts 1/29/2021 6000 Series 214 Calibration Menu • PT Phase A Scale – Calibrates PT phase A voltage input – Monitor Gen Overview (Volts L-L), or Gen Phases (Volts L-N) and adjust PT Phase A scale until these values match measured generator voltage on A phase • PT Phase B Scale; PT Phase C Scale – Same as above, but for B and C phases of Gen. 1/29/2021 6000 Series 215 Calibration Menu • CT Phase A Scale – calibrates CT Phase A sensing of 6000 control – Load generator and monitor gen. currents in phase overview menu. – Measure actual gen. currents with clamp on ammeter, or panel ammeter. – Calibrate phase A CT reading in phase overview. 1/29/2021 6000 Series 216 Calibration Menu • CT Phase B Scale; CT Phase C scale – Same as CT setup for phase A. • If CT polarity is reversed, that phase will read negative KW when loaded in the Phase overview menu. • If CTs are on the incorrect phases, then KVAR readings in phase overview will be off. 1/29/2021 6000 Series 217 Calibration Menu • Bus PT Scale – Similar to Gen PT scaling, but this scale is for single phase bus PT input to the 6000 control. – Put 6000 control synchroniser in “check” mode in synchroniser setup menu. – Start engine in run/load mode to a live bus. – Monitor Synchroscope status menu. Observe and calibrate U: volts reading until measured matches monitored. 1/29/2021 6000 Series 218 Calibration Menu • Synchroscope – Calibrates phase angle error detection of 6000 control. – Factory calibrated for zero phase angle error between bus and A phase generator inputs – With synchroniser in “check” mode, and a live bus, monitor the synchroscope menu of the 6000 control for “phase angle”. 1/29/2021 6000 Series 219 Calibration Menu • Synchroscope (continued) – Monitor Voltage across open gen contactor/breaker or panel synchroscope for phase angle error between generator and bus. – Adjust synchroscope calibration for lowest voltage across gen breaker, or 12 o’clock reading on an external synchroscope. 1/29/2021 6000 Series 220 Calibration Menu • Analog inputs to VCOs (Voltage Controlled Osc.) Freq. (Hz) Analog Input 1/29/2021 6000 Series 221 Calibration Menu • Voltage Controlled Oscillators Increasing offset Freq. Decreasing offset Analog Input 1/29/2021 6000 Series 222 Calibration Menu • Voltage Controlled Oscillators Increasing gain Decreasing gain 1/29/2021 6000 Series 223 Calibration Menu • Battery VCO Gain – Sets slope of battery VCO over operating range • Battery VCO Offset – Sets level, or offset of Battery VCO over operating range – Battery Voltage is a linear increasing type VCO function 1/29/2021 6000 Series 224 Calibration Menu • Battery VCO VCO Freq. Battery Voltage 1/29/2021 6000 Series 225 Calibration Menu • Ain1 VCO Gain – Oil Pressure sensor input – 0-200 ohm sensor on engine is a direct, mostly linear VCO function – Sets slope of oil pressure input to VCO frequency – Monitor Engine Overview menu of 6000 control and compare to measured oil pressure of engine with engine running at rated speed. – Adjust gain for proper oil pressure reading while engine is operating 1/29/2021 6000 Series 226 Calibration Menu • Ain1 VCO Offset – Sets level, or offset of oil pressure input to VCO frequency – Set to read 0 psi in Engine Overview menu of 6000 control with engine off. – Gain and Offset DO affect each other, so it is neccessary to check adjustments at both ends of the scale (0 psi to operating psi) if an adjustment is made to either gain or offset. 1/29/2021 6000 Series 227 Calibration Menu • Oil Pressure VCO VCO Freq. Oil Presssure (OHMS) 1/29/2021 6000 Series 228 Calibration Menu • Ain2 VCO Gain – Water Temperature VCO – Inverse, Non-Linear 0-200 ohm engine mounted sensor – Utilises Shunt resistor dip switches on back of GCP (SW-1 7 and 8 ON). These resistors help to linearize the sensor input 1/29/2021 6000 Series 229 Calibration Menu • Ain2 VCO Gain – Sets slope of water temp. input to VCO frequency – Monitor Engine Overview menu of 6000 control and compare to measured water temperature of engine with at low operating temperature. – Adjust gain for proper water temperature reading while engine is operating 1/29/2021 6000 Series 230 Calibration Menu • Ain2 VCO Offset – Sets level, or offset of VCO frequency to water temperature slope. – Monitor Engine overview, and with engine operating at normal temperature, adjust Ain2 VCO offset for proper temperature reading – This is an inverse function. Sensor resistance DECREASES as engine temp increases 1/29/2021 6000 Series 231 Calibration Menu • Water Temp VCO Sensor without shunt Sensor with shunt VCO Freq. Water Temperature 1/29/2021 6000 Series 232 Calibration Menu • Testing of a sample of Oil pressure sensors with the 6000 control has shown the typical sensor to require the following gain/offset for Ain1 in the calibration menu: • Gain 0.0242 • Offset -11.90 1/29/2021 6000 Series 233 Calibration Menu • Testing of a sample of Water Temp Sensors has shown the typical temp sensor to require following gain and offset settings: • Gain -0.0389 • Offset 246.0 • Shunt Resistor Switches 7 and 8 closed on SW-1 of 6000 control 1/29/2021 6000 Series 234 Calibration Menu • NetComm Dropouts – The number of lost or corrupted network communications tolerated by the recieving unit. – Excess numbers of NetComm Dropouts on network due to faulty wiring, improper shielding, or improper setup will result in the unit experiencing the dropouts to flash intermittantly in the Sequencing Menu of the 6000 control. Typically set at 5 to 10 dropouts. 1/29/2021 6000 Series 235 Communications •Two different versions of software - PC Tools Monitor only - PC Tools Control & Monitor •Three different pieces of hardware - Hardwired connection up to 500m - Modem for connection over telephone - Call back on alarm activation 1/29/2021 6000 Series 236 Communications •PC1: Provides remote monitoring up to 500 metres from generator •PC2: Allows remote monitoring and control up to 500 metres from generator •Difference is software 1/29/2021 6000 Series 237 Communications •Tel 1: Provides remote monitoring over the telephone system •Tel 2: Allows remote monitoring and control over the telephone system •Difference is software •Hardware difference over PC panel is addition of modem 1/29/2021 6000 Series 238 Communications •Tel 3: Allows remote monitoring and control over the telephone system •Same hardware as Tel 1 & 2 with addition of AutoDial unit •Optional facility industry standard Modbus protocol interface allowing compatibility with most BMS or SCADA systems 1/29/2021 6000 Series 239 Communications Screen shot from PC Tools: monitor only 1/29/2021 6000 Series 240 Communications Screen shot from PC Tools: Control and monitor 1/29/2021 6000 Series 241 Communications PC Tools has two different applications associated with it - Servlink and - GCP 6000 1/29/2021 6000 Series 242 RS-485 & RS-422 Networks as shown on FG Wilson electrical schematic 1/29/2021 6000 Series 243 RS-485 The RS-485 Network is used to connect all units in a multiple system ie 6200 or 6400. Wires 70 (RS-485 +),71 (RS-485-),72 (5vDC+) & 73 (5vDC-) should be connected to all machines. Switches 3/4, 3/7 & 3/8 should be set to ON, on the first and last machines only 8 7 6 5 4 3 2 1 8 RS-485 Termination + 7 RS-485 Termination 4 RS-485 +5vDC Pull Up SW 3 1/29/2021 6000 Series 244 RS-422 The RS-422 Network is used to connect the 6000 control system to the PC or Tel panel when the remote communications option is selected. In a multiple unit application the connection from the PC/Tel connects only one machine and then each unit is connect in series using wires 61(RxD+), 62 (RxD-), 63(TxD+) & 64(TxD-). Switches 3/1, 3/2 & 3/3 should be set to On, on the first and last machines only 8 3 RS-422 Termination RxD7 6 5 4 3 2 1 1/29/2021 2 RS-422 +5vDC Pull Up 1 RS-422 Termination RxD+ 6000 Series 245
