Operation Manual PLC-HMI Upgrade.pdf

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Operation Manual PLC/HMI Upgrade

Armed Forces Retirement Center

Paralleling Switchgear and Controls

Kohler Project Number: SGP-1297 SO. No. 1019754586

March 28, 2021

RP Power Contact: Jeff Robichaux

Operation Manual – PLC/HMI Upgrade SGP# SO# Date

Armed Forces Retirement Center 1297 1019754586 3/28/2021

Safety Precautions and Instructions

Revisions History

Section 1 Preparation, Storage, and Installation

1.1 Introduction

1.2 Inspection at Time of Delivery

1.3 Handling

1.3.1 Moving Sections

1.3.2 Lifting Sections

1.4 Storage

1.5 Installation

1.5.1 Bus and Power Connections

1.5.2 Interconnection Wiring

Section 2 Introduction

2.1 Overview

2.2 Interpretation of Sequence Tables

2.2.1 System State Symbol Key

2.2.2 Automatic / Standby Mode (System Initial State)

2.2.3 Normal Operational Sequences

2.2.4 Responses to Abnormal Conditions

2.2.5 First-on Logic

2.2.6 Additional Notes

Section 3 Sequences of Operation - Automatic

3.1 Utility Source Failure: Loads Transferred to Generators

3.1.1 Overview

3.1.2 Sequence

3.1.3 Responses to Abnormal Conditions

3.2 Utility Source Restored: Open-transition Load Transfer from Gens

3.2.1 Overview

3.2.2 Sequence

3.2.3 Responses to Abnormal Conditions

3.3 Utility Source Restored: Soft-transition Load Transfer from Gens

3.3.1 Overview

3.3.2 Sequence

3.3.3 Responses to Abnormal Conditions

3.4 Generator Management Mode

3.4.1 Description

3.4.2 Controls

3.4.3 Setpoints

3.5 Load Management (Load Add/Shed)

3.5.1 Description

3.5.2 Load Add

3.5.3 Load Shed

3.5.4 User Adjustable Parameters

3.5.5 User Adjustable Load Priority Levels

3.6 Fire Pump Operation Mode

3.6.1 Preliminary Conditions

3.6.2 Initiation

3.6.3 Completion

Section 4 Sequences of Operation – Manually-initiated

4.1 Initiate Isolate Mode: Open-transition Load Transfer, Utility to Gens

4.1.1 Overview

4.1.2 Sequence

4.1.3 Responses to Abnormal Conditions

4.2 Initiate Isolate Mode: Soft-transition Load Transfer, Utility to Gens

4.2.1 Overview

4.2.2 Sequence

4.2.3 Responses to Abnormal Conditions

4.3 End Isolate Mode: Open-transition Load Transfer, Gens to Utility

4.3.1 Overview

4.3.2 Sequence

4.3.3 Responses to Abnormal Conditions

4.4 End Isolate Mode: Soft-transition Load Transfer, Gens to Utility

4.4.1 Overview

4.4.2 Sequence

4.4.3 Responses to Abnormal Conditions

4.5 No-load Test

4.5.1 Overview

4.5.2 Sequence - Start

4.5.3 Responses to Abnormal Conditions

4.5.4 Sequence - Stop

4.6 Generator Synchronization Test

4.6.1 Overview

4.6.2 Sequence – Start

4.6.3 Responses to Abnormal Conditions

4.6.4 Sequence – Stop

4.6.5 Responses to Abnormal Conditions

Section 5 Manual Controls

5.1 Indicating Lights

5.2 Controls

Section 6 Human - Machine Interface (HMI)

6.1 Common Screen Features

6.1.1 Status and Alarm Banner

6.1.2 Navigation

6.1.3 How to Navigate

6.1.4 How to Change a Set point

6.1.5 Security

6.1.6 Security – Auto Logout

6.1.7 Circuit Breaker Status

6.1.8 Bus Status

6.1.9 Generator Set Status

6.1.10 Source Selection

6.1.11 Screenshot

6.2 Overview

6.3 Status

6.3.1 Status > Genset > Electrical

6.3.2 Status > Genset > Mechanical

6.3.3 Status > Genset > All

6.3.4 Status > Genset > Run Report

6.3.5 Status > Utility Electrical

6.3.6 Status > Tie Electrical

6.4 Control

6.4.1 Control > Genset > Control

6.4.2 Control > Breakers

6.4.3 Control > Tests > No Load Test

6.4.4 Control > Tests > Sync

6.4.5 Control > U to G Open Transfer

6.4.6 Control > U to G Soft Transfer

6.4.7 Control > G to U Open Transfer

6.4.8 Control > G to U Soft Transfer

6.5 Load Management

6.5.1 Control

6.5.2 Setup

6.6 Generator Management

6.6.1 Gen Mgmt

6.7 Setup

6.7.1 Setup > Genset > Relays

6.7.2 Setup > Genset > Setpoints

6.7.3 Setup > Genset Sync

6.7.4 Setup > Genset kW Control

6.7.5 Setup > Genset kW Share

6.7.6 Setup > Genset kVAR Share

6.7.7 Setup > Utility Sync

6.7.8 Setup > Tie Sync

6.7.9 Setup > System > Setpoints

6.7.10 Setup > Utility Setpoints

6.7.11 Setup > System > Meter

6.7.12 Setup > System > Ranges

6.8 Alarms

6.8.1 Alarms > Active

6.8.2 Alarms > Not in Auto

6.8.3 Alarms > History

6.9 Reports

6.9.1 Reports

6.10 Trend

6.10.1 Trend > Genset Electrical

6.10.2 Trend > Genset Mechanical

6.11 Help

6.11.1 Help > Legend

6.11.2 Help > Project Information

6.11.3 Help > Load Management State History

6.11.4 Help > Generator State History

6.11.5 Help > Main State History

6.11.6 Help > Diagnostics

6.11.7 Help > Versions

Safety Precautions and Instructions

IMPORTANT SAFETY

INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE

THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions:

Danger, Warning, Caution, and Notice.

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition.

Replace missing or damaged decals.

Battery

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Explosion.

Can cause severe injury or death. Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

Hazardous Voltage/ Moving Parts

HIGH VOLTAGE.

Will cause severe injury or death.

Only authorized personnel should open the enclosure.

5 kV and above.

Hazardous voltage.

death.

Disconnect all power sources before opening the enclosure.

death.

Disconnect all power sources before servicing. Install the barrier after adjustments, maintenance, or servicing.

death.

Multiple power sources can automatically energize the switchgear. Disconnect all power sources before working inside the enclosure.

death.

Only authorized personnel should open the enclosure.

Grounding electrical equipment.

Hazardous voltage can cause severe injury or death.

Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Servicing the switchgear.

Hazardous voltage can cause severe injury or death.

De-energize all power sources before servicing. Turn off the main circuit breakers of all switchgear power sources and disable all generator sets as follows: (1) Move all generator set master controller switches to the OFF position. (2) Disconnect power to all battery chargers. (3) Disconnect all battery cables, negative (-) leads first.

Reconnect negative (-) leads last when reconnecting the battery cables after servicing. Follow these precautions to prevent the starting of generator sets by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Before servicing any components inside the enclosure: (1) Remove all jewelry.

(2) Stand on a dry, approved electrically insulated mat. (3) Test circuits with a voltmeter to verify that they are de-energized.

Testing live electrical circuits.

Hazardous voltage or current can cause severe injury or death.

Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests.

Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure.

(4) Be prepared for the system to operate automatically.

(600 volts and under)

NOTICE

Foreign material contamination.

Cover the switchgear during installation to keep dirt, grit, metal drill chips, and other debris out of the components. After installation, operate the circuit breaker(s) and/or transfer switch(es) to verify that they operate freely.

Revisions History

Ver Remarks

- Initial Submittal for Approval.

1 Updated per startup.

2 Updated per PLC/HMI upgrade.

Notes:

Section 1 Preparation, Storage, and Installation

1.1 Introduction

This manual contains instructions for the installation, operation, and maintenance of Kohler® Switchgear.

Read this instruction book carefully before unpacking, installing, or attempting to operate the equipment.

These instructions apply to Kohler® Switchgear installations. Detailed instructions for other system components are included in the Component Manuals section of the document binder.

Read and follow the safety precautions included with this manual. Pay attention to the decals on the equipment and follow the instructions below.

All personnel involved in handling, site preparation, installation, testing, operation, and maintenance should be thoroughly familiar with the information in this instruction manuals and customer drawings provided before working on this equipment.

Never make interlocks inoperative or operate the equipment with any safety barriers removed.

Always assume that all high-voltage parts are energized until it is certain that they are de-energized.

Use only test equipment rated for the service intended.

Check interconnection diagrams and make sure there are no potential backfeed sources.

Never disconnect the main trip source of energized equipment.

Do not open a circuit breaker door unless the circuit breaker is tripped.

Move circuit breakers to the disconnected position before removing rear access panels.

Use out-of-service tags and padlocks when working on equipment. Leave tags in place until the work is completed and the equipment is ready to be put back into service.

The complete assembly arrangement determines if the top or bottom contacts are the line side; both can be energized when the circuit breaker is removed from the compartment.

Disconnect all high voltage to the switchgear before accessing the horizontal bus compartment.

Do not use liquid fire extinguishers of water on electrical fires. Before extinguishing fires within the assembly, be absolutely certain that the main power source is disconnected and the main and all feeder breakers are tripped.

1.2 Inspection at Time of Delivery

At time of delivery inspect the switchgear and loose parts for signs of shipping damage. If damage and/or rough handling are evident, immediately file a damage claim with the transportation company and promptly notify the factory sales office.

1.3 Handling

To avoid equipment damage, do not turn the switchgear backward or tilt it more than 15 degrees from vertical while handling. Do not lay the switchgear on its back.

1.3.1 Moving Sections

Move sections carefully and keep them upright. Do not drop or bump sections. Mishandling can cause damage to delicate meters and instruments as well as distortion to doors and steel framework.

Secure sections to their shipping skids before moving them. The skid provides extra rigidity to the frame, preventing distortion to the bottom in transit.

1.3.2 Lifting Sections

Size lifting equipment according to the switchgear weight displayed on the outside of each crate.

Lift the switchgear vertically from the base using spanner or spreader bars to avoid crushing or distorting the frame. Rigging should lift the switchgear upright. Minimize rigging tension and compressive load on sections by maintaining an angle of less than 45 degrees between the lifting cables and vertical.

To allow top lifting with lifting plates, use spanner or spreader bars when lifting vertically as described above.

1.4 Storage

If the assembly is stored prior to installation, keep it in a clean, dry, well-ventilated area with a mean temperature of approximately 21°C (70°F). Place dust covers over circuit breakers. If space heaters are furnished in the assembly, energize them from an external source. Refer to schematic and wiring diagrams for a logical connection point and for voltage and power requirements.

If no space heaters are installed in the assembly, and the area is cold and damp, use a temporary heating source within the assembly. A minimum of 200 watts of heat per cell is recommended. Avoid greasy, smoking heaters that can deposit carbon on insulation, causing tracking and eventual insulation breakdowns.

If the space heaters are normally energized from the assembly control power transformer, open the control power transformer secondary circuit breaker, remove the primary current-limiting fuses, and install and out-of-service tag before energizing the space heaters. This prevents backfeed to the main bus through the control power transformer.

1.5 Installation

After moving the switchgear into its permanent position, level and fasten it securely to either the floor or floor channels.

1.5.1 Bus and Power Connections

Install splice plates and bus pieces removed for shipment.

Refer to the Bus Bar Bolt Torque decal located on the switchgear back panel. There is a decal on either side of the shipping break. The Bus Bar Bolt Torque decal lists torque specifications for connecting the bus bar to the splice plates. Bus bar bolt sizes are 3/8-16 or 1/2-13.

Assemble the bus with the bolt extending toward the back of the switchgear cubicle so the flat washer is against the bus. Then install the spring washer and the nut.

Check the power cables for damage and verify phasing before connecting power cables to the generator(s) and switchgear.

When connecting the cables use the torque values printed on the decal located on the switchgear back panel or use the connector manufacturer's torque specs.

1.5.2 Interconnection Wiring

Refer to the interconnection drawings for external connections to other equipment.

Use stranded wire with insulated compression lugs when making control interconnects between the switchgear and the generator set(s). Consider the load current and length of the run when sizing wire and cable. Refer to the drawing list in the Wiring Diagrams section of this manual for other drawings pertaining to the switchgear.

Use the instructions provided with test equipment for hi-pot and megger tests of electrical cables and equipment. Check wiring terminations and bus and circuit breaker lug connections for tightness before energizing the equipment.

Section 2 Introduction

2.1 Overview

The Kohler-supplied switchgear is designed to control two (2) Kohler 2250kW generators in parallel with each other.

A 15-inch HMI (touchscreen) at the control section allows operator control of the system. The Kohler-provided PLC-based control system, consisting of one CPU per generator and a master system controller, controls the generators and all breaker operation when selected to Automatic Mode. The system is designed to work with two Kohler DEC-550 genset controllers.

The switchgear has the following modes of operation:

Emergency Mode (Loss of utility source)

Isolate Mode (open or closed transition)

Generator Sync Test

No Load Test

Generator Management

Load Management (through the load shed relay)

2.2 Interpretation of Sequence Tables

2.2.1 System State Symbol Key

Dist Bus Power distribution bus normally fed from utility source.

Gen Bus Generator paralleling bus fed from gens 1 and 2.

U1 Utility main breaker at switchgear (distribution bus).

T1 Generator source tie breaker that ties the distribution bus (“Dist Bus”) and generator bus

(“Gen Bus”) for the purpose of serving system loads from generators.

X Indicates breaker closed condition.

O Indicates breaker open condition.

D Bus de-energized.

E Bus energized.

2.2.2 Automatic / Standby Mode (System Initial State)

Initial State

U1 Dist Bus T1 Gen Bus

X E O D

2.2.3 Normal Operational Sequences

Tables indicating pre-determined (normal) sequences of operation are provided on the following pages.

Each step of each sequence is numbered and each step’s triggering event and system response are listed.

2.2.4 Responses to Abnormal Conditions

Note that below each normal sequence of operation, a failure table is provided that describes how the system responds to a failure of any step in the sequence. Should such a failure occur, the horn sounds and an alarm message is displayed on the HMI, and the system responds as described on the failure step. Touching the “Horn Silence” pushbutton silences the horn. The horn is re-activated if new alarms are issued.

2.2.5 First-on Logic

Generator first-on logic prevents multiple generators from simultaneously closing to a dead paralleling bus.

2.2.6 Additional Notes

Timers All time delays are user-adjustable. Any timer values shown are for illustrative purposes only.

Section 3 Sequences of Operation - Automatic

3.1 Utility Source Failure: Loads Transferred to Generators

3.1.1 Overview

When the utility lost signal is received by the Kohler PLC, the utility source failure timer in the PLC starts.

When this timer expires, the loads transfer to generator power.

3.1.2 Sequence

State

Step Event Response If Fail

1 Utility lost signal received. Utility source failure timer starts. A

2 Utility source failure timer expires. Utility breaker U1 commanded to open. B

All available generators start.

3 Utility breaker U1 opened. Open-transfer timer starts.

Required gens-online-bypass timer starts.

Startup Shed Option:

Based on the load management settings, loads on Dist Bus are shed (load shed relay energizes).

4 The first generator reaches rated voltage and frequency.

The first generator breaker commanded to close.

5 First generator breaker closed successfully. The remaining generator reaches rated voltage and frequency.

The remaining generator synchronizes to the bus and close its circuit breaker.

C, D

6 Required generators are online and the open-transfer timer expired.

Gen source tie breaker T1 commanded to close.

E

7 Gen source tie breaker T1 closed. Dist Bus is on generator power.

Required gens-online-bypass timer stops.

8 Dist Bus is on generator power. Startup Shed Option:

Based on the load management settings, loads are added to the Dist Bus (load shed relay de-energizes).

F

Generator Management Option:

Becomes active if in “auto” and all loads have been added.

Final State

O E X E

3.1.3 Responses to Abnormal Conditions

Step Fail

Event System Response Operator Action

A Utility source power returns before utility source failure timer expires.

Dist Bus remains on utility source power.

No operator action required.

B Utility breaker U1 fails to open.

Utility source remains failed:

Dist Bus is without power. Gen source tie breaker T1 does not close.

Option #1:

Reset the fail-to-open alarm.

System attempts to open utility breaker U1. When breaker commanded to open, transfer automatically continues.

Option #2:

1. Turn U1 Breaker Auto/Manual switch located on door of section 1 to “Manual”.

2. Turn U1 Breaker Control switch located on door of section 1 to “Trip” to manually open utility breaker.

3. When breaker opens, transfer automatically continues.

Utility source returns:

Dist Bus remains on utility source. Following the expiration of the utility “source stable” bypass timer, the generators breakers open. The generators shut down after their cooldown timers expire.

No operator action required.

C Required gens-online-bypass timer expires before required number of generators are online.

At Least One Generator Online:

Based on the load management settings, loads on Dist Bus are shed (load shed relay energized). Gen source tie breaker T1 commanded to close.

Based on the load management settings, loads are then added to the Dist Bus (load shed relay de-energized).

No operator action required.

Event System Response Operator Action

D Number of generators available is below gens-online requirement.

All Available Generators Online:

Based on the load management settings, loads on Dist Bus are shed (load shed relay energized). Gen source tie breaker T1 commanded to close.

Based on the load management settings, loads are then added to the Dist Bus (load shed relay de-energized).

No operator action required.

E Gen source tie breaker T1 fails to close.

Utility source remains failed:

Dist Bus is without power. The generators remain running, paralleled on the generator bus.

Option #1:

Reset the fail-to-close alarm.

System attempts to close gen source tie breaker T1.

Option #2:

1. Turn T1 Breaker Auto/Manual switch located on door of section 3 to “Manual”.

2. Turn T1 Breaker Control switch located on door of section 3 to “Close” to manually close tie breaker.

Utility source returns:

Utility breaker U1 commanded to close following the expiration of the utility “source stable” bypass timer. The online generators open their breakers and shut down after their cooldown timers expire.

No operator action required.

F One generator fails after being online or Dist Bus becomes overloaded.

Based on the load management settings, loads on Dist Bus are shed (load shed relay energized).

The operator can override the automatic load shed controls.

Generator Management Option:

If offline due to generator management, available offline generator starts.

3.2 Utility Source Restored: Open-transition Load Transfer from Gens

3.2.1 Overview

When the utility lost signal going to the Kohler PLC is removed, the utility “return” timer in the PLC starts if the “return control” switch is in “auto”. When this timer expires, loads transfer from generator power back to utility source power. This sequence describes an open transfer between power sources.

Note: There will be a loss of power to the load bus during the open transfer time delay.

3.2.2 Sequence

State

1 Utility lost signal is removed. Utility “return” timer starts. A

2 Utility “return” timer expires. Gen source tie breaker T1 commanded to open.

B

3 Gen source tie breaker T1 opened. Open-transfer timer starts.

4 Open-transfer timer expires. Utility breaker U1 commanded to close. C

5 Utility breaker U1 closed. Dist Bus is on utility source power.

6 Dist Bus is on utility source power. The generator breakers open and the generators shut down after their cooldown timers expire.

D

Load Management Option:

If shed, loads add back on (load shed relay de-energizes).

3.2.3 Responses to Abnormal Conditions

Event System Response Operator Action

A Utility source power is lost before utility “return” timer expires.

Dist Bus remains on generator power.

No operator action required.

B Gen source tie breaker T1 fails to open.

Utility breaker U1 does not close. The transfer is cancelled.

Dist Bus remains on generator power.

Option #1:

Reset the fail-to-open alarm.

Utility “return” timer restarts.

Option #2:

1. Turn T1 Breaker Auto/Manual switch located on door of section 3 to “Manual”.

2. Turn T1 Breaker Control switch located on door of section 3 to “Trip” to manually open tie breaker.

3. Utility breaker U1 automatically closes following the open transfer time delay.

4. Generator breakers automatically open.

Generators shut down once their cooldown timers expire.

C Utility breaker U1 fails to close.

Based on the load management settings, loads on Dist Bus are shed (load shed relay energizes).

Any offline generators are signaled to start. After the required number of generators are online, gen source tie breaker T1 commanded to close.

Dist Bus is back on generator power. Based on the load management settings, loads are added to the Dist Bus (load shed

Reset the fail-to-close alarm.

Utility “return” timer restarts when Dist Bus is on generator power.

Event System Response Operator Action

D One or more generator breakers fail to open.

The generator continues to run on the generator bus.

Option #1:

Reset the fail-to-open alarm.

System attempts to open generator breaker.

Option #2:

1. Turn Breaker Auto/Manual switch located on door to “Manual”.

2. Turn Breaker Control switch located on door to “Trip” to manually open generator breaker.

3.3 Utility Source Restored: Soft-transition Load Transfer from Gens

3.3.1 Overview

When utility source voltage and frequency return within tolerance, the utility “return” timer in the PLC starts if the “return control” switch is in “auto”. When this timer expires, loads transfer from generator power back to utility source power. This sequence describes a soft transfer between power sources.

3.3.2 Sequence

State

1 Utility source within tolerance. Utility “return” timer starts. A

2 Utility “return” timer expires. The generators synchronize to utility source across utility breaker U1.

B

3 Generators synchronized to utility source. Utility breaker U1 commanded to close. C

4 Utility breaker U1 closed. The generators unload at a preset kW/sec rate.

D/E

Load-transfer timer starts.

5 The power flow through the gen source tie breaker T1 reaches the disconnect setpoint.

Gen source tie breaker T1 commanded to open.

F

6 Gen source tie breaker T1 opened. Dist Bus is on utility source power.

Load-transfer timer stops.

7 Dist Bus is on utility source power. The generator breakers open and the generators shut down after their cooldown timers expire.

G

Load Management Option:

3.3.3 Responses to Abnormal Conditions

Event System Response Operator Action

A Utility source power is lost before utility “return” timer expires.

Dist Bus remains on generator power.

No operator action required.

B Generators fail to synchronize to utility source.

Dist Bus remains on generator power.

Option #1:

Reset the “fail to synchronize” alarm. Utility “return” timer restarts.

Option #2:

Place the Return Control switch in the “Manual” position. Then perform an open transfer to utility as described in Section 4.3.

C Utility breaker U1 fails to close.

Dist Bus remains on generator power.

Reset the fail-to-close alarm.

Utility “return” timer restarts.

D The load-transfer timer expires.

The gen source tie breaker T1 commanded to open.

No operator action required.

E Intertie protection relay trips.

Utility breaker U1 trips.

Dist Bus remains on generator power.

Reset the lockout relay located on the utility section door. Place the utility breaker back in Auto on the HMI.

F Gen source tie breaker T1 fails to open.

The generator breakers open. Option #1:

Reset the fail-to-open alarm.

System attempts to open gen source tie breaker T1.

Option #2:

1. Turn T1 Breaker Auto/Manual switch located on door of section 3 to “Manual”.

2. Turn T1 Breaker Control switch located on door of section 3 to “Trip” to manually open tie breaker.

Event System Response Operator Action

G One or more generator breakers fail to open.

The generator continues to run on the generator bus.

Option #1:

Reset the fail-to-open alarm.

System attempts to open generator breaker.

Option #2:

1. Turn Breaker Auto/Manual switch located on door to “Manual”.

2. Turn Breaker Control switch located on door

3.4 Generator Management Mode

3.4.1 Description

When all generators are on-line and paralleled due to a loss of utility or Isolate Mode and total load falls below an operator preset percent of online capacity, generator management optimizes the number of on-line gensets based on the system load level (total load)/(number of on-line generators). Generator management starts and stops gensets as required. The order in which the generators start and stop can be based on generator run time or operator selectable.

Higher priority units are sequenced on in the order of their priority and taken off in reverse priority. A genset goes off-line by decreasing its load at a preset kW/sec rate until it reaches its disconnect setpoint.

When it reaches its disconnect setpoint, its circuit breaker opens. A genset goes back on-line by synchronizing and closing its breaker, then loading at a preset kW/sec rate unit it is sharing the on-line load with the running generators. Operator defined set points determine percent load level and the time delay at which genset will be brought on or taken offline.

If an on-line genset fails or has a prealarm, Generator Management is aborted and all off-line generator sets start and go on-line.

3.4.2 Controls

The HMI has the following control switches for generator management:

Generator Management Control

Auto Touch to enable generator management

Off Touch to turn off generator management. If a generator was shut down due to light load, it restarts and goes back online

Order Selection

Runtime Touch to prioritize gensets based on run time. The generator with the lowest run time is the lead unit

Manual Touch to prioritize gensets based on operator selected order

3.4.3 Setpoints

The HMI has the following setpoints for generator management:

Start

%System Load The start delay timer starts when the generator percent loaded exceeds this setpoint.

Delay The length of time that the generators must be loaded above the start percent system load before the system starts the next generator.

Stop

% System Load The stop timer starts when the generator percent loaded falls below this setpoint.

Delay The length of time that the generators must be below stop percent system load before the system stops a generator.

Overload

% System Load The overload delay timer starts when the generator percent loaded exceeds this setpoint.

Delay The length of time that the generators must be loaded above the overload percent system load before the system starts the next generator.

3.5 Load Management (Load Add/Shed)

3.5.1 Description

Load management (load add/shed) provides control of customers loads. There is one load shed relay used for controlling non-priority 1 loads. When the relay is energized, loads are shed. When the relay is de-energized, loads are added.

Load add is based on the number of gensets on-line and/or kW capacity. The method of load add is user configurable.

3.5.2 Load Add

If kW Capacity and Number of Generators are enabled, the system will first enter Generator on-line load add and then enter kW capacity if all the loads are not on-line.

kW Capacity After a preset time (the timer starts after one generator is on-line) expires which allows all available generators to come on-line, the system will enter kW capacity load add. The system will add the load step if the current system load, plus the kW setpoint of the load priority is less than the kW overload setpoint.

Number of Generators On-Line

The loads are added based on the number of generators on-line.

3.5.3 Load Shed

When the system is on the generator power and all loads have been added, the loads can be configured to shed based on one or more of the following methods:

Load Shed Methods

Generator Failure Loads are shed based on the number of gensets failed. Priority loads are configured to shed based on the receipt of a generator failure.

kW Overload Lower priority loads are shed based on the generator capacity (% loaded) exceeding the generator overload setpoint for a preset amount of time.

Under Frequency Lower priority loads are shed if the generator bus drops below the under frequency shed setpoint for a preset amount of time. There will only be one level of under frequency load shedding.

3.5.4 User Adjustable Parameters

The HMI will have the following user adjustable parameters for load add/shed:

Adjustable Load Add/Shed Parameters kW Capacity Load Add Startup Delay Timer (Sec)

Sets the length of time between when the generator circuit breaker is closed and the kW capacity-based load add starts.

Expected Load (kW) Sets the anticipated kW of the load connected to the load shed relay.

kW Overload Setpoint (% Load)

Sets the percent load on the generators that, when exceeded, starts the kW overload shed timer. Load will sequentially shed until the overload condition no longer exists.

kW Overload Shed Timer (Sec)

Sets the length of time after an overload before the next priority load sheds.

Under Frequency Load Shed Setpoint (Hz)

Sets the frequency of the generator bus that, when below, starts the load shed timers.

Under Frequency Load Shed Timer (Sec)

Sets the length of time the generator bus must be below its under frequency load shed setpoint before it signals lower priority loads to shed.

3.5.5 User Adjustable Load Priority Levels

The HMI will have the following user adjustable parameters for setting the load priority levels to shed or add:

Load Shed Priority Level

Deadbus Upon a Utility Lost signal, the system will energize the load shed relay.

EF Shed Upon a generator failure, the system will energize the load shed relay.

UF Shed Upon the generator bus reaching the under frequency setpoint, the system will energize the load shed relay.

Overload Shed Upon a generator reaching the overload setpoint, the system will energize the load shed relay.

Load Add Priority Level

1 GOL Add Upon one generator on-line, the system will add each priority equal to and less than this setpoint.

2 GOL Add Upon two generators on-line, the system will add each priority equal to and less than this setpoint.

3.6 Fire Pump Operation Mode

The Fire Pump Operation Mode starts and parallels the generators for the purpose of supplying power to the customer’s fire pump controller.

Note: If a utility failure is sensed during this mode, the utility main breaker (U1) is opened and the bus tie breaker (T1) closed, and the system automatically continues in Emergency Mode.

3.6.1 Preliminary Conditions

All generator controls must be selected to “Auto”.

3.6.2 Initiation

Receipt of a dry contact input from the customer’s equipment initiates Fire Pump Operation Mode according to the following sequence:

1. All generators start.

2. The first generator to produce rated voltage and frequency is connected to the dead generator bus via closure of its respective breaker, energizing the bus and the fire pump load takeoff.

3. The remaining generator synchronizes to the energized generator bus. Once synchronized, its circuit breaker closes, and the generators share the fire pump load for the duration of fire pump operation.

Note: Load-shed relaying is not required in Fire Pump Operation Mode.

3.6.3 Completion

Removal of the dry contact input from the customer’s equipment causes the system to return to Normal Mode from Fire Pump Operation Mode according to the following:

1. All generator breakers open, de-energizing the fire-pump load takeoff.

2. All generators run for a preset time to cool down.

3. All generators shut down.

Section 4 Sequences of Operation – Manually-initiated

4.1 Initiate Isolate Mode: Open-transition Load Transfer, Utility to Gens

4.1.1 Overview

This sequence describes an operator-initiated open transfer of the loads from utility source power to generator power.

Note: There will be a loss of power to the loads during the open transfer time delay.

4.1.2 Sequence

State

1 Operator touches the “start” button. All available generators start.

2 The first generator reaches rated voltage and frequency.

3 The remaining generator reaches rated voltage and frequency.

The remaining generator synchronizes to the bus and closes its circuit breaker.

A

4 Required generators are online. Utility breaker U1 commanded to open. B

5 Utility breaker U1 opened. Open-transfer timer starts.

Startup Shed Option:

Based on the load management settings, loads on Dist Bus are shed (load shed relay energizes).

6 Open-transfer timer expires. Gen source tie breaker T1 commanded

C

7 Gen source tie breaker T1 closed. Dist Bus is on generator power.

8 Dist Bus is on generator power. Startup Shed Option:

Based on the load management settings, loads are added to the Dist Bus (load shed relay de-energizes).

D

Generator Management Option:

Becomes active if in “auto” and all loads

4.1.3 Responses to Abnormal Conditions

Event System Response Operator Action

A Number of generators available is below gens-online requirement.

The available online generators run in parallel on the generator bus.

Option #1:

Reset the generator failure and/or alarm.

System attempts to bring the generator online.

Option #2:

Touch the “continue” button to continue the transfer with the remaining available generators.

Based on load management settings, loads on Dist Bus are shed (load shed relay energizes).

Option #3:

Touch the “cancel” button to end the transfer and remain on utility source power. The online generators open their breakers and shut down after their cooldown timers expire.

B Utility breaker U1 fails to open.

Dist Bus remains on utility source power. The transfer is cancelled. The online generators open their breakers and shut down after their cooldown timers expire.

Reset the fail-to-open alarm.

Touch the “start” button to re-initiate the transfer to generator power.

C Gen source tie breaker T1 fails to close.

Utility breaker U1 commanded to close. Dist Bus is back on utility source power. The transfer is cancelled. The online generators open their breakers and shut down after their cooldown timers expire.

Reset the fail-to-close alarm.

Touch the “start” button to re-initiate the transfer.

D One or more generators fail after being online or Dist Bus becomes overloaded.

Based on the load management settings, loads on Dist Bus are shed (load shed relay energizes).

If all generators fail, gen source tie breaker T1 commanded to open. Utility breaker U1 commanded to close after the open-transfer timer expires.

The operator can override the automatic load shed controls.

Generator Management Option:

If offline due to generator management, available offline

4.2 Initiate Isolate Mode: Soft-transition Load Transfer, Utility to Gens

4.2.1 Overview

This sequence describes an operator-initiated soft transfer of the loads from utility source power to generator power.

4.2.2 Sequence

State

1 Operator touches “start” button. All available generators start.

2 The first generator reaches rated voltage and frequency.

3 The remaining generator reaches rated voltage and frequency.

The remaining generator synchronizes to the bus and closes its circuit breaker.

A

4 Required generators are online. Generators synchronize to utility source across gen source tie breaker T1.

B

5 Generators synchronized to utility source. Gen source tie breaker T1 commanded to close.

C

6 Gen source tie breaker T1 closed. The generators load at a preset kW/sec rate.

D/E

Load-transfer timer starts.

7 The power flow through utility breaker U1 reaches the disconnect setpoint.

Utility breaker U1 commanded to open. F

8 Utility breaker U1 opened. Dist Bus is on generator power.

Load-transfer timer stops.

9 Dist Bus is on generator power. Generator Management Option:

Becomes active if in “auto” and all loads

G

4.2.3 Responses to Abnormal Conditions

Event System Response Operator Action

A Number of generators available is below gens-online requirement.

The available online generators run in parallel on the generator bus.

Option #1:

Reset the generator failure and/or alarm.

System attempts to bring the generator online.

Option #2:

Touch the “continue” button to continue the transfer with the remaining available generators.

Based on load management settings, loads on Dist Bus are

Option #3:

Touch the “cancel” button to end the transfer and remain on utility source power. The online generators open their breakers and shut down after their cooldown timers expire.

B Generators fail to synchronize to utility.

The online generators run in parallel on the generator bus.

Option #1:

Reset the “fail to synchronize” alarm. System restarts the synchronization process.

Option #2:

Touch the “cancel” button to end the transfer and remain on utility source power. The online generators open their breakers and shut down after their

Option #3:

Perform an open transfer to generators as described in Section 4.1.

Event System Response Operator Action

C Gen source tie breaker T1 fails to close.

The online generators run in parallel on the generator bus.

Option #1:

Reset the fail-to-close alarm.

System restarts the synchronization process.

Option #2:

Touch the “cancel” button to end the transfer and remain on utility source power. The online generators open their breakers and shut down after their cooldown timers expire.

D The load-transfer timer expires.

Utility breaker U1 commanded to open.

No operator action required.

E Intertie protection relay trips.

Utility breaker U1 trips.

Dist Bus on generator power.

Reset the lockout relay located on the utility section door. Place the utility breaker back in Auto on the HMI.

F Utility breaker U1 fails to open.

Gen source tie breaker T1 commanded to open after the power flow through it reaches the disconnect setpoint, or after the load-transfer timer expires.

Dist Bus remains on utility source power.

The transfer is cancelled. The online generators open their breakers and shut down after their cooldown timers expire.

Reset the fail-to-open alarm.

Touch the “start” button to re-initiate the transfer to generator power.

G One or more generators fail after being online or Dist Bus becomes overloaded.

Based on the load management settings, loads on Dist Bus are

If all generators fail, gen source tie breaker T1 commanded to open. Utility breaker U1 commanded to close after the open-transfer timer expires.

The operator can override the automatic load shed controls.

Generator Management Option:

If offline due to generator management, available offline

4.3 End Isolate Mode: Open-transition Load Transfer, Gens to Utility

4.3.1 Overview

This sequence describes an operator-initiated open transfer of the loads from generator power to utility source power.

Note: There will be a loss of power to the load bus during the open transfer time delay.

4.3.2 Sequence

State

1 Operator touches the “start” button. Gen source tie breaker T1 commanded to open.

A

2 Gen source tie breaker T1 opened. Open-transfer timer starts.

3 Open-transfer timer expires. Utility breaker U1 commanded to close. B

4 Utility breaker U1 closed. Dist Bus is on utility source power.

5 Dist Bus is on utility source power. The generator breakers open and the generators shut down after their cooldown timers expire.

C

Load Management Option:

4.3.3 Responses to Abnormal Conditions

Event System Response Operator Action

A Gen source tie breaker T1 fails to open.

Utility breaker U1 does not close. The transfer is cancelled.

Dist Bus remains on generator power.

Option #1:

Reset the fail-to-open alarm.

Touch the “start” button to re-initiate the transfer to utility power.

Option #2:

1. Turn T1 Breaker Auto/Manual switch located on door of section 3 to “Manual”.

2. Turn T1 Breaker Control switch located on door of section 3 to “Trip” to manually open tie breaker.

3. Utility breaker U1 automatically closes following the open transfer time delay.

4. Generator breakers automatically open.

Generators shut down once their cooldown timers expire.

B Utility breaker U1 fails to close.

Based on the load management settings, loads on Dist Bus are

Any offline generators are signaled to start. After the required number of generators are online, gen source tie breaker T1 commanded to close.

Dist Bus is back on generator power. Based on the load management settings, loads are added to the Dist Bus (load shed

Reset the fail-to-close alarm.

Touch the “start” button to re-initiate the transfer to utility power.

Event System Response Operator Action

C One or more generator breakers fail to open.

The generator continues to run on the generator bus.

Option #1:

Reset the fail-to-open alarm.

System attempts to open generator breaker.

Option #2:

1. Turn Breaker Auto/Manual switch located on door to “Manual”.

2. Turn Breaker Control switch located on door

4.4 End Isolate Mode: Soft-transition Load Transfer, Gens to Utility

4.4.1 Overview

This sequence describes an operator-initiated soft transfer of the loads from generator power to utility source power.

4.4.2 Sequence

State

1 Operator touches the “start” button. The generators synchronize to utility source across utility breaker U1.

A

2 Generators synchronized to utility source. Utility breaker U1 commanded to close. B

3 Utility breaker U1 closed. The generators unload at a preset kW/sec rate.

C/D

Load-transfer timer starts.

4 The power flow through the gen source tie breaker T1 reaches the disconnect setpoint.

Gen source tie breaker T1 commanded to open.

E

5 Gen source tie breaker T1 opened. Dist Bus is on utility source power.

Load-transfer timer stops.

6 Dist Bus is on utility source power. The generator breakers open and the generators shut down after their cooldown timers expire.

F

Load Management Option:

4.4.3 Responses to Abnormal Conditions

Event System Response Operator Action

A Generators fail to synchronize to utility source.

Transfer is cancelled. Dist Bus remains on generator power.

Option #1:

Reset the “fail to synchronize” alarm. Touch the “start” button to reinitiate the transfer to utility power.

Option #2:

Perform an open transfer to utility as described in Section 4.3.

B Utility breaker U1 fails to close.

Transfer is cancelled. Dist Bus remains on generator power.

Reset the fail-to-close alarm.

Touch the “start” button to reinitiate the transfer to utility power.

C The load-transfer timer expires.

The gen source tie breaker T1 commanded to open.

No operator action required.

D Intertie protection relay trips.

Utility breaker U1 trips.

Dist Bus remains on generator power.

Reset the lockout relay located on the utility section door. Place the utility breaker back in Auto on the HMI.

E Gen source tie breaker T1 fails to open.

The generator breakers open. Option #1:

Reset the fail-to-open alarm.

System attempts to open gen source tie breaker T1.

Option #2:

1. Turn T1 Breaker Auto/Manual switch located on door of section 3 to “Manual”.

2. Turn T1 Breaker Control switch located on door of section 3 to “Trip” to manually open tie breaker.

F One or more generator breakers fail to open.

The generator continues to run on the generator bus.

Option #1:

Reset the fail-to-open alarm.

System attempts to open generator breaker.

Option #2:

1. Turn Breaker Auto/Manual switch located on door to “Manual”.

2. Turn Breaker Control switch located on door

4.5 No-load Test

4.5.1 Overview

This test starts the selected generators without closing to Gen Bus for the purpose of verifying engine-generator operation.

Operator may select individual or all generators for the test. Only the selected generators start for the test.

Operator may set the duration of the run to a preset time. Upon expiration of that timer, the no-load test ends.

Note: If utility power is lost, the no-load test is cancelled and the system goes into emergency mode.

4.5.2 Sequence - Start

State

1 Operator touches the “start” button. All selected generators start. A

2 Each generator reaches rated voltage and frequency.

Generator breakers do not close.

Test-duration timer starts when its setpoint is greater than zero.

4.5.3 Responses to Abnormal Conditions

Event System Response Operator Action

A One or more generators fail to start.

All other generators remain running.

No-load test is cancelled if all generators are unavailable.

Reset the generator failure.

System attempts to start failed generator once generator is selected for the test.

4.5.4 Sequence - Stop

State

1 Operator touches the “stop” button or the Test Duration timer expires.

The generators shut down after their

4.6 Generator Synchronization Test

4.6.1 Overview

This test starts and parallels the selected generators to the generator bus for the purpose of verifying generator operation. No load transfer occurs during this test. Gen source tie breaker T1 remains open.

Operator may select individual or all generators for the test. Only the selected generators start for the test.

Operator may set the duration of the run to a preset time. Upon expiration of that timer, the gen sync test ends.

Note: If utility power is lost, the gen sync test is cancelled and the system goes into emergency mode.

4.6.2 Sequence – Start

State

1 Operator touches the Start button. All selected generators start. A

2 The first generator reaches rated voltage and frequency.

The first generator breaker closes. A

3 The remaining generator reaches rated voltage and frequency.

The remaining generator synchronizes to the generator bus and closes its breaker.

A

4 All selected generator breakers are closed. Test Duration timer starts when its setpoint is greater than zero.

B

X E O E

4.6.3 Responses to Abnormal Conditions

Event System Response Operator Action

A One or both generators fail to start or go online.

Other generator remains running if both were selected.

Gen Sync Test is cancelled if both generators are unavailable.

Reset the generator failure and/or alarm.

System attempts to bring the generator online once generator is selected for the test.

B One or more generators fail after being on-line.

Other generator remains running if both were selected.

Gen Sync Test is cancelled if all generators are unavailable.

Reset the generator failure.

System attempts to bring the generator online once generator is selected for the test.

4.6.4 Sequence – Stop

State

X E O E

1 Operator touches the “stop” button or the Test Duration timer expires.

The generator breakers open and the generators shut down after their

A

4.6.5 Responses to Abnormal Conditions

Event System Response Operator Action

A One or more generator breakers fail to open.

The generator remains running. Option #1:

Reset the fail-to-open alarm.

System attempts to open generator breaker.

Option #2:

Turn Breaker Control switch located on door of section 4 or 5 to “Trip” to manually open gen breaker.

Section 5 Manual Controls

5.1 Indicating Lights

Refer to drawing SGP-1297, sheets M1 thru M5 for indicator light locations.

Light Indication

Engine Running

(White)

The generator is running.

Breaker Closed

(Red)

The circuit breaker closed.

Breaker Open

(Green)

The circuit breaker opened.

GPR Tripped

(Amber)

The generator circuit breaker opened due to a protective relay fault. The generator continues to run.

GPR Shutdown

(Amber)

The…