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```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
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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:
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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
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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
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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
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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
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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.
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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
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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
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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.
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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
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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.
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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
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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
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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
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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
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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
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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
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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
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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
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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 &amp; Generator Protections
•Available in 12 Languages
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22
Language Options
•English
•German
•Swedish
•French
•Danish
•Italian
•Finnish
•Dutch
•Icelandic
•Portuguese
•Norwegian
•Spanish
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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
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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
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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
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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
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27
Synchronising
• Phase Match Synchronisation
• 3 Mode Operation
– run, check, permissive
• Voltage Matching
• Dead Bus Closing
• Synch Timer
• Reclose Attempt/Timer
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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
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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
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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
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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
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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
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33
Controller Interface
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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
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35
6000 Series Controller: 6100
• Single Unit No Parallel-6100 Mode (AMF)
M
M
G
LOAD
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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
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37
6000 Series Controller
• Typical 6000 Switch Configuration
AUTO
OFF
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TEST
RUN
6000 Series
38
FG Wilson Schematic for 6000 Series
Control Mode Switch
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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
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40
6000 Series Controller: 6100
• Single Unit Prime Power
G
LOAD
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41
6000 Series Controller: 6100
• Single Unit Prime Power
•
•
•
•
No Mains PT Required
No Mains Aux. Required
Dead Bus Closing
Isochronous Load Control
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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
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43
6000 Series Controller: 6200
• Multi Unit, No Parallel-6200 Mode (AMF)
Up to 8 Generators
G
G
G
LOAD
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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
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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
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46
FG Wilson Schematic for 6000 Series
Control Mode Switch for Master 6200
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47
FG Wilson Schematic for 6000 Series
Control Mode Switch for Master 6200
GST
1GSR
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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.
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49
6000 Series Controller: 6200
• Multiple Unit-6200 Mode (Prime Power)
Up to 8 Generators
G
G
LOAD
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50
6000 Series Controller: 6200
• Multiple Unit-6200 Mode (Prime Power)
•
•
•
•
No Mains PT
No Mains Aux.
Dead Bus Closing
Load Dependant Auto Sequencing
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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
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52
6000 Series Controller: 6300
• Single Unit Parallel - 6300 Mode
M
M
G
LOAD
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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
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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
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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
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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.
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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.
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58
6000 Series Controller: 6400
• Multiple Unit, Mains Parallel (6400 Mode)
M
External PLC
ControlLogic
G
M
M
M
G
LOAD
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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
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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.
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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
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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
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63
Keypad Detail
• Vertical Keys
AlarmReset
Resets Alarms
Clears Alarm Ind.
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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.
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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
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66
Screen Detail
Top six lines (blue section)
- Status Display
Bottom two lines (white section)
- Tunables Display
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67
Status Menus
• Status Menus
CONTROL OVERVIEW
ENGINE OVERVIEW
GEN OVERVIEW
GEN PHASES
SYNCHROSCOPE
ALARM/EVENT LOG
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68
Status Menus
• Status Menus (continued)
I/O STATUS
SEQUENCING
-Accessed by pressing the down arrow to scroll
down through status menu screen.
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69
Status Menus
• Control Overview Engine off Line
UNIT: 1
ENGINE: OFF
MAINS:
AUTO
ALARMS: 0
GEN:
OFF
UNIT: 1
PRIORITY: 1
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70
Status Menus
• Engine On Line on Isolated Bus
UNIT: 1
ENGINE: RUN
MAINS:
AUTO
ALARMS: 0
GEN:
ISOCH
UNIT: 1
PRIORITY: 1
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71
Status Menus
• Engine Base Loaded To Mains
UNIT: 1
ENGINE: RUN
MAINS:
AUTO
ALARMS: 0
GEN:
BASELOAD
UNIT: 1
PRIORITY: 1
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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
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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
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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.
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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)
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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
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77
Status Menus
• Synchroscope
Slip
Phase
****
****
Mains/Bus: Mains
Dead Bus: Yes
(SYNCHRONIZER STATUS)
A: 0.0
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6000 Series
Volts
****
U: 0.0
78
Status Menus
• Alarm/Event Log
Unack Faults: 0
Faults Listing:
None Recorded
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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
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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.
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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
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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:
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0
0
6000 Series
83
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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
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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
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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
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87
Discrete Outputs
•
•
•
•
7- Local Bus PT Connect
8- Mains PT Disconnect
9- Mains Breaker Trip
10- Gen Breaker Trip
• 11- Audible Alarm
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88
Status Menus
• Sequencing Menu
Unit:
1
Oper:
Prty:
1
Master Unit:
1
Next On: All
Next Off:
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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:
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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
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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
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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
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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
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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
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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
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96
Configure Menu
• System Frequency (50/60 Hz.)
– Used as a basis for generator waveform
analysis
– Defines typical operating frequency of
generator
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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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; Alarm Menu
• Reverse Power
KW
+
Reverse
Power
Delay
0
KW
Reverse
Power
Time
Reverse Power
1/29/2021
6000 Series
144
Shutdowns &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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 &amp; 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.
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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
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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.
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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
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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
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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
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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
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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
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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.
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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
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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
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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...
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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.
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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
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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.
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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.
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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.
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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.
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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”.
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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.
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6000 Series
220
Calibration Menu
• Analog inputs to VCOs (Voltage Controlled Osc.)
Freq.
(Hz)
Analog Input
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221
Calibration Menu
• Voltage Controlled Oscillators
Increasing offset
Freq.
Decreasing offset
Analog Input
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222
Calibration Menu
• Voltage Controlled Oscillators
Increasing gain
Decreasing gain
1/29/2021
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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
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224
Calibration Menu
• Battery VCO
VCO
Freq.
Battery Voltage
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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
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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.
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227
Calibration Menu
• Oil Pressure VCO
VCO
Freq.
Oil Presssure
(OHMS)
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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
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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
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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
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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.
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235
Communications
•Two different versions of software
- PC Tools Monitor only
- PC Tools Control &amp; Monitor
•Three different pieces of hardware
- Hardwired connection up to 500m
- Modem for connection over telephone
- Call back on alarm activation
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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
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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
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238
Communications
•Tel 3: Allows remote monitoring and control
over the telephone system
•Same hardware as Tel 1 &amp; 2 with addition of
AutoDial unit
•Optional facility industry standard Modbus
protocol interface allowing compatibility with
most BMS or SCADA systems
1/29/2021
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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
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242
RS-485 &amp; 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+) &amp; 73 (5vDC-)
should be connected to all machines.
Switches 3/4, 3/7 &amp; 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
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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+) &amp; 64(TxD-).
Switches 3/1, 3/2 &amp; 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
```