Kohler Low Voltage Switchgear Operation Manual.pdf

Operation Manual

Switchgear

Low Voltage Switchgear

Veterans Affairs Medical Center Fayetteville, Arkansas

Kohler Project: SGP-1320

VAMC Fayetteville LV Operation Manual

SGP-1320 Page 2 of 63 Rev.: 6/10

Safety Precautions and Instructions

Revision History

Section 1 Preparation, Storage, and Installation

1.1 Introduction

1.2 Inspection at Time of Delivery

1.3 Handling

1.4 Moving Sections

1.5 Lifting Sections

1.6 Storage

1.7 Installation

1.7.1 Bus and Power Connections

1.7.2 Interconnection Wiring

1.8 Decision-Maker

550 Generator Set Controller Settings

Section 2 Project Identification

2.1 Project Numbers

2.2 How to Read Sequence Tables

2.2.1 Sequence Tables

2.2.2 Legend

2.2.3 Normal Operational Sequences

2.2.4 Glossary

2.2.5 Additional Notes

2.2.6 Circuit Breaker Reference

Section 3 Sequence of Operation – Automatic

3.1 Emergency Mode – Enter

3.1.1 Overview

3.1.2 HMI Screen

3.1.3 Transfer Ready Conditions

3.1.4 Automatic Action

3.1.5 Sequence – Emergency Mode Enter

3.1.6 Responses to Abnormal Conditions – Emergency Mode Enter

3.2 Emergency Mode – Exit

3.2.1 Overview

3.2.2 HMI Screen

3.2.3 Transfer Ready Conditions

3.2.4 Automatic Action

3.2.5 Sequence – Emergency Mode Exit

3.2.6 Responses to Abnormal Conditions – Emergency Mode Exit

3.3 Generator Management

3.3.1 Overview

3.3.2 HMI Screen

3.3.3 Controls

3.3.4 Setpoints

3.4 Load Management (Load Add/Shed)

3.4.1 Overview

3.4.2 HMI Screen

3.4.3 Load Add

3.4.4 Load Shed

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Section 4 Sequence of Operation – Operator Initiated

4.1 No Load Test – Start

4.1.1 Overview

4.1.2 HMI Screen

4.1.3 Transfer Ready Conditions

4.1.4 Operator Action – Start

4.1.5 Sequence – No Load Test – Start

4.1.6 Responses to Abnormal Conditions – No Load Test – Start

4.2 No Load Test – Stop

4.2.1 Overview

4.2.2 HMI Screen

4.2.3 Transfer Ready Conditions

4.2.4 Operator Action – Stop

4.2.5 Sequence – No Load Test – Stop

4.2.6 Responses to Abnormal Conditions – No Load Test – Stop

Section 5 Status

5.1 System Status Indication

5.2 Control Line-up – Indicating Lights

5.2.1 Master Control Door

5.2.2 Generator Control Door

5.2.3 Feeder/Tie Breaker Control Door

5.3 Control Line-up – Metering

5.3.1 Generator

Section 6 Control

6.1 Generator Control Cabinet Switches

6.2 Master Control Cabinet Switches

Section 7 Human-Machine Interface (HMI)

7.1 Common Screen Features

7.1.1 Alarm Banner

7.1.2 Setting Adjust and Display Areas

7.1.3 How to Change a Setpoint

7.1.4 Navigation Tabs

7.1.5 Security Levels

7.1.6 How to Log In

7.1.7 How to Log Out

7.1.8 Circuit Breaker Status

7.1.9 Bus Status

7.1.10 Generator Set Status

7.2 HMI Overview Screen

7.2.1 Overview

7.3 HMI Status Screens

7.3.1 Status > LV Genset Summary

7.3.2 Status > Utility

7.3.3 Status > PLC

7.3.4 Status > LV Multi Gen

7.3.5 Status > ATS

7.4 HMI Control Screens

7.4.1 Control > LV Gensets

7.4.2 Control > LV Tie

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7.4.3 Control > LV Feeders

7.4.4 Control > LV Gen Mgmt

7.4.5 Control > Timed Test

7.4.6 Control > No Load Test

7.5 HMI Setup Screens

7.5.1 Setup > LV Add/Shed

7.5.2 Setup > LV Relays

7.5.3 Setup > Settings

7.5.4 Setup > HMI

7.6 HMI Alarms Screens

7.6.1 Alarms > Alarm List

7.6.2 Alarms > Not in Auto

7.6.3 Alarms > History

7.7 HMI Help Screen

7.7.1 Help > Legend

Section 8 Bill of Material

8.1 Switchgear

Section 9 Project Drawings

Section 10 Major Component Manuals

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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.

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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.

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Revision History

Rev Remarks

6/10 Initial Release

Notes:

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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 manual 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 or 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.

1.4 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.

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1.5 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.

1.6 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 an out-of-service tag before energizing the space heaters. This prevents backfeed to the main bus through the control power transformer.

1.7 Installation

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

1.7.1 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 specifications.

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1.7.2 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 Project Drawings 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.

1.8 Decision-Maker® 550 Generator Set Controller Settings

The Decision-Maker

550 generator set controller communicates to its PLC using Modbus. Verify that the following 550 controller communication parameters are set:

Modbus: Yes Connection Type: Remote Single Primary Port: RS-485 Modbus Address: 1 Baud Rate: 19200

Note: The Decision-Maker® 550 controller must be in Remote Programming Mode so that the controller settings can be adjusted remotely from the switchgear.

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Section 2 Project Identification

2.1 Project Numbers

Kohler Project Number SGP-1320

Ship Date

Start-up Date

Start-up Technician

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2.2 How to Read Sequence Tables

2.2.1 Sequence Tables

The sequence of operation for each mode is provided in a tabular format. Each step of the sequence is numbered, and each step’s triggering event and the system response are listed. The system response to a failure is listed following the table:

Step Note Event Response If Fail

2.2.2 Legend

G1 Generator Circuit Breaker No. 1 G2 Generator Circuit Breaker No. 2 T1 Generator Tie Circuit Breaker LB1 Load Bus No. 1 LB2 Load Bus No. 2

D De-energized E Energized X Circuit Breaker Closed O Circuit Breaker Open

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 the system response are listed.

2.2.4 Glossary

MV – Medium voltage switchgear.

LV – Low voltage switchgear.

Area Protection – ATS Mode operation used to force the ATS to transfer to generator power. ATS will remain on generator power as long as area protection input is present. If generator power is lost, the ATS will transfer back to normal source.

2.2.5 Additional Notes

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

2.2.6 Circuit Breaker Reference

Throughout the remainder of the manual the Generator Circuit Breaker No. 1 will be referred to as generator breaker G1.

Throughout the remainder of the manual the Generator Circuit Breaker No. 2 will be referred to as generator breaker G2.

Throughout the remainder of the manual the Generator Tie Circuit Breaker will be referred to as tie breaker T1.

Throughout the remainder of the manual the Load Bus No. 1 will be referred to as Bus LB1.

Throughout the remainder of the manual the Load Bus No. 2 will be referred to as Bus LB2.

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Section 3 Sequence of Operation – Automatic

3.1 Emergency Mode – Enter

3.1.1 Overview

The LV switchgear will supply power to the connected automatic transfer switches.

3.1.2 HMI Screen

See Section 7.2.1.

3.1.3 Transfer Ready Conditions

The following must be true for the system to enter Emergency Mode:

At least one generator is available.

3.1.4 Automatic Action

When one or more ATS start signals are received from an ATS, the following sequence occurs.

3.1.5 Sequence – Emergency Mode Enter

Initial State

G1 LB1 T1 LB2 G2

O D X D O

1 ATS start signal received. One or more generators start.

Inhibit transfer signal sent to priority-2 automatic transfer switches.

2 The first generator reaches rated voltage and frequency. (Assume generator 1.)

Generator breaker G1 closes.

3 The second generator reaches rated voltage and frequency.

The second generator synchronizes to Bus LB2.

4 The second generator is synchronized to Bus LB2.

Generator breaker G2 closes. A

5 Two generators are on-line. Inhibit transfer signal to priority-2 transfer switches removed.

B

Final State

X E X E X

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3.1.6 Responses to Abnormal Conditions – Emergency Mode Enter

The horn will sound and an alarm message will be displayed on the HMI for any of the failures listed below. Pressing the Horn Silence button will silence the horn. The horn will be reactivated if new alarms are issued.

Step Fail

Event System Response Operator Action

A, B One generator is out of service, fails to start, or fails go on-line.

The priority-2 transfer switches will remain in Inhibit Transfer Mode. When the medium voltage generators come on-line, the priority-2 transfer switches will see the return of normal power. The inhibit transfer signal is removed after the medium voltage generators are on-line.

Select the Reset button on the HMI to reset and restart the generator.

See Section 7.4.1.

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3.2 Emergency Mode – Exit

3.2.1 Overview

The low voltage generators will remain running until the area protection start signal from the medium voltage switchgear is removed. The removal of the area protection signal allows the transfer switches to operate based on their internal sensing and setpoints.

3.2.2 HMI Screen

See Section 7.2.1.

3.2.3 Transfer Ready Conditions

The following must be true for the system to exit Emergency Mode:

The control system is in Auto.

3.2.4 Automatic Action

When all of the ATS start signals are removed, the following sequence occurs.

3.2.5 Sequence – Emergency Mode Exit

Initial State

1 All ATS engine start signals are removed.

Generator breakers G1 and G2 open. A

2 Generator breakers G1 and G2 opened.

Generator Cooldown timers start.

3 Generator Cooldown timers expired. The generator(s) stop running.

Initial State

3.2.6 Responses to Abnormal Conditions – Emergency Mode Exit

below. Pressing the Horn Silence button will silence the horn. The horn will be reactivated if new alarms are issued.

Step Fail

Event System Response Operator Action

A Generator breaker fails to open.

The generator remains running until operator intervention.

Manualy open generator breaker

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3.3 Generator Management

3.3.1 Overview

Generator Management optimizes the number of on-line generators based on the kW demand of the load. Generator Management will start and stop the generators as required. The order the generators start and stop can be based on generator run time or can be operator-selectable. The user assigns each generator a priority level. Higher priority units are sequenced on in the order of their priority and taken off in reverse priority. The generators soft load and unload. User-defined setpoints determine percent load level and the time delay at which a generator will be brought on-line or taken off-line.

If an on-line generator fails or has a pre-alarm, Generator Management will be aborted and all off-line generator sets will start and go on-line.

3.3.2 HMI Screen

See Section 7.4.4.

3.3.3 Controls

The HMI will have the following control selectors for Generator Management:

Generator Management Control

Auto Select to enable Generator Management Mode.

Off Select to turn off Generator Management Mode. If system was in Generator Management Mode and generators where shut down due to light load, they will restart and go back on-line.

Order Selection

Runtime Select to prioritize generators based on run time. The generator with the lowest run time will be the lead unit.

Manual Select to prioritize generators based on operator-selected order.

3.3.4 Setpoints

The HMI will have the following setpoints for Generator Management:

Device Description

Start

% 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 kW setpoint before the system starts the next generator.

Stop

% Load The Stop timer starts when the generator percent loaded is below this setpoint with the next generator off-line.

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

Overload

% 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 kW setpoint before the system starts the next generator.

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3.4 Load Management (Load Add/Shed)

3.4.1 Overview

The Load Add/Shed system will control the following priority-2 equipment load automatic transfer switches: ATS-X1, ATS-E1, and ATS-CEP. The Load Add/Shed system will be coordinated with the Load Add/Shed system in the medium voltage switchgear line-up. In the event of generator failure, the medium voltage switchgear will shed load and allow the low voltage transfer switches to connect the medium voltage generators.

3.4.2 HMI Screen

See Section 7.5.1.

3.4.3 Load Add

kW Capacity After one generator is on-line and the MV generators are not running, the kW Capacity Start timer starts.

When this timer expires, the priority-2 loads are sequentially added until adding the next load would cause the generators to exceed their overload setpoint. The next load is added if the system load plus the kW setpoint of the next load priority is less than the kW overload setpoint. The system will wait for the duration of the Load Add timer before adding the next priority.

3.4.4 Load Shed

In the event of a load shed condition on the low voltage switchgear, the medium voltage switchgear will shed load and allow the low voltage transfer switches to connect the medium voltage generators.

If the medium voltage generator is not on-line, the system will load shed the priority-2 transfer switches based on one or more of the following methods:

Generator Failure The system will shed all of the priority-2 transfer switches.

kW Overload The priority-2 transfer switches are sequentially shed. They are shed when the generators exceed an overload setpoint for a preset amount of time. Loads shed (feeder breaker open) sequentially (lowest to highest) based on the Load Shed timer until the generator loading is below the kW overload setpoint. The kW overload shed can also be configured to shed a block of preset loads.

Underfrequency The system will shed all of the priority-2 transfer switches.

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Section 4 Sequence of Operation – Operator Initiated

4.1 No Load Test – Start

4.1.1 Overview

This test starts and parallels the generators for the purpose of periodically verifying switchgear and generator operation.

4.1.2 HMI Screen

See Section 7.4.6.

4.1.3 Transfer Ready Conditions

The following must be true for the system to enter Emergency Mode:

At least one generator is available.

4.1.4 Operator Action – Start

Select the No Load Test Start button on the HMI.

4.1.5 Sequence – No Load Test – Start

Initial State

1 No Load Test start initiated. Generators start.

2 The first generator reaches rated voltage and frequency. (Assume generator 1.)

Generator breaker G1 closes.

3 The second generator reaches rated voltage and frequency.

The second generator synchronizes to Bus LB2.

4 The second generator is synchronized to Bus LB2.

Generator breaker G2 closes. A

5 Two generators are on-line. System operating in No Load Test Mode.

B

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4.1.6 Responses to Abnormal Conditions – No Load Test – Start below. Pressing the Horn Silence button will silence the horn. The horn will be reactivated if new alarms are issued.

Step Fail

Event System Response Operator Action

A, B One generator is out of service, fails to start, or fails go on-line.

System alarms. Select the Reset button on the HMI to reset and restart the generator.

See Section 7.4.1.

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4.2 No Load Test – Stop

4.2.1 Overview

This will stop the testing of the generator paralleling system.

4.2.2 HMI Screen

See Section 7.4.6.

4.2.3 Transfer Ready Conditions

The following must be true for the system to exit Emergency Mode:

The control system is in Auto.

4.2.4 Operator Action – Stop

Select the No Load Test Stop button on the HMI.

4.2.5 Sequence – No Load Test – Stop

Initial State

1 No Load Test stop initiated. Generator breakers G1 and G2 open. A

2 Generator breakers G1 and G2 are open.

Generator Cooldown timers start.

3 Generator Cooldown timers expired. The generators stop running.

4.2.6 Responses to Abnormal Conditions – No Load Test – Stop

below. Pressing the Horn Silence button will silence the horn. The horn will be reactivated if new alarms are issued.

Step Fail

Event System Response Operator Action

A Generator breaker fails to open.

The generator remains running until operator intervention.

Manually open the generator breaker.

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Section 5 Status

5.1 System Status Indication

Status indications for the generators, breakers, events, alarms, electrical and mechanical quantities, etc., are accessible through the HMI display. Audible alarms are provided at the HMI, and pilot lights are provided to indicate manual/auto status, primary and standby PLC failure, generator alarm and status, breaker status for feeder breakers, and availability of utility source.

Analog metering is provided for displaying generator output (frequency, voltage, current, power).

5.2 Control Line-up – Indicating Lights

5.2.1 Master Control Door

Light Indication

Amber

Alarm There is an active alarm/shutdown in the system.

Red

PLC Failure Primary The primary PLC has failed.

PLC Failure Standby

The standby master PLC/CPU is not in run or not synced with the primary.

5.2.2 Generator Control Door

Light Indication

Green

Breaker Open The circuit breaker is open.

White

Engine Running The engine is running.

Red

Breaker Closed The circuit breaker is closed.

5.2.3 Feeder/Tie Breaker Control Door

Light Indication

Green

Breaker Open The circuit breaker is open.

Red

Breaker Closed The circuit breaker is closed.

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5.3 Control Line-up – Metering

5.3.1 Generator

Note: Each generator will have the following analog meter.

Name Scale

Watt 0–1200 kW

Note: Each generator will have the following digital power meter.

Manufacturer

Square D PM 820

Note: The sync panel will have the following analog meters.

Name Scale

Volts–Running 0–600 V

Volts–Incoming 0–600 V

Freq–Running 55–65 Hz

Freq–Incoming 55–65 Hz

Synchroscope No Scale

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Section 6 Control

6.1 Generator Control Cabinet Switches

Note: The following control switches will be mounted on each generator’s control section.

Device Description

Engine Control

Off Turns the generator off. If the generator was running, the generator will stop and the generator circuit breaker will open. The generator will stop after completing a cooldown cycle.

Auto Places the starting and stopping of the generator under the control of its PLC.

Run The generator will start and run at rated speed and voltage.

Shutdown Stops the generator. If the generator was running, the generator will stop and the generator circuit breaker will open.

Emergency Stop

Emergency Stop Immediately stops the generator and opens the generator circuit breaker.

Prevents the generator from starting.

Reset

Reset Press to reset engine alarms and shutdowns.

Voltage Adjust

Lower Decreases the generator voltage.

Raise Increases the generator voltage.

Speed Adjust

Lower Decreases the generator speed.

Raise Increases the generator speed.

Circuit Breaker – Open/Close Switch

Open Opens the generator breaker. In order for the generator breaker to open, the circuit breaker control switch must be in Manual.

Close Closes the generator circuit breaker. In order for the generator breaker to close, the circuit breaker control switch must be in Manual, the sync control switch must be on, and one of the following conditions must be true:

Generator bus must be live and generator must be synchronized to the bus.

The generator bus is dead.

Circuit Breaker – Auto/Manual Switch

Auto Places the circuit breaker under the control of the PLC.

Manual Disables PLC control and enables operation of the circuit breaker open/close switch.

Sync Control

Off Turns off the synchronizer.

Auto Places the synchronizer under the control of the PLC.

Check Used to test the synchronizer. The generator will synchronize, but the generator breaker will not be issued a close signal.

Synchroscope

Off Turns off the sync panel. The handle can be removed in this position.

On Turns on the Synchroscope.

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6.2 Master Control Cabinet Switches

Note: The following control switches will be mounted on the master control section door.

Device Description

Remote Control (Key)

Disable Disables SCADA or remote HMI control of the system.

Enable Enables SCADA and remote control.

System Control Switch

Manual Disables automatic (PLC) control of the system.

Auto (PLC/HMI) Enables automatic control of the system.

Horn Silence Button

Horn Silence Press to silence the horn. The horn will be re-activated if new alarms are issued.

Reset

Reset Press to reset fault.

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Section 7 Human-Machine Interface (HMI)

The HMI is a 15-inch color touchscreen with graphic and alphanumeric displays and buttons that allow monitoring, configuration, and control of the switchgear.

7.1 Common Screen Features

The illustration below identifies the areas of a typical screen.

1. Alarm Banner (Top, All Screens)

2. Status Indication

3. Metering Displays (Analog and/or Digital)

4. Control Buttons

5. Setpoints (Adjustable)

6. Navigation Tabs (Bottom, All Screens)

Status, metering, control, and/or setpoints (items 2–5) will appear in various combinations in the central area of each screen.

7.1.1 Alarm Banner

Active alarms are displayed on the alarm banner located on the top of each screen. The following indicators appear with the alarm banner:

Indicator Description

Communications Status Indicator. Located in the upper left corner of every screen.

2, 3

2, 3

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Not in Auto Indicator. Located in the upper left corner of the screen. Flashes yellow if one or more control switches are not in Auto.

Active Alarm Indicator. Located in the upper left corner of the screen.

Security Login Status Indicator. Shows the date, time, and active (logged in) security level.

7.1.2 Setting Adjust and Display Areas

The following screen areas will be found throughout the HMI:

Area Description

Setting Adjust Touch Area (raised gray box with numbers). Select to open keypad.

Display Area (light blue).

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7.1.3 How to Change a Setpoint

To change a setpoint, touch the setpoint area twice to access the numeric keypad.

Note: If touching a setpoint does not access the numeric keypad, that setpoint is password-protected.

Using the numeric keypad, enter the new value. Then select Enter to save. The keypad will close and the new value will be shown in the setting area.

7.1.4 Navigation Tabs

Use the blue tabs at the left of the display to move to different pages. To choose a page, select a blue tab, wait for the selection menu, and then select the page you want to go to.

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Control Description

Generator Set Selection Control. On pages that display data for more than one generator or utility, select the Increase or Decrease button to choose a specific generator.

Select to open the Alarm Acknowledge and Reset popup.

Select to move forward or backward through previously viewed pages or to go to the home page.

7.1.5 Security Levels

Control and Indicator Description

The touchscreen has three security levels:

View Only: Can view all status, control, and setpoint information.

User: Allows access to controls and customer-configurable setpoints.

Setup: Allows access to controls, customer-configurable setpoints, and system setup/tuning setpoints.

7.1.6 How to Log In

All settings are password-protected. To enter the password, follow the steps listed below:

Procedure Display

Step 1

Select the Security Login button in the upper right corner of the display. The Security Login dialog box will pop up.

Step 2

Select the User Name entry area and use the keypad to enter the user name. Then select the Password entry area and use the keypad to enter the password. After entering the password, select the Log In button.

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7.1.7 How to Log Out

Procedure Display

Step 1

Select the Security Login button in the upper right corner of the display. The Security Login dialog box will pop up.

Step 2

Select the Log Out button on the Security Login dialog box. The security level will change to View Only.

7.1.8 Circuit Breaker Status

Circuit Breaker Closed and in Auto (red).

Circuit Breaker Open and in Auto (green).

Circuit Breaker Racked Out or Future Breaker (gray).

Circuit Breaker Closed and Not in Auto (blue with red).

Circuit Breaker Open and Not in Auto (blue with green).

Circuit Breaker Open and Currently Under Synchronization (Synchroscope).

7.1.9 Bus Status

Energized (red).

De-energized (green).

7.1.10 Generator Set Status

Not Running (green).

Running (red).

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7.2 HMI Overview Screen

7.2.1 Overview

The Overview screen displays an animated one-line representation of the system.

Status indicators illuminate to indicate active functions.

Status Description

Overview Mode Status

Utility Lost Utility source has been lost. This will remain illuminated until the Utility has returned to normal.

Isolate Mode Isolate mode has been initiated. This will remain illuminated until the mode has been stopped.

No Load Test The generators are running due to an operator-initiated No-Load Test start command. This will remain illuminated until the No-Load Test is manually stopped.

Return to Util Transfer to Utility has been initiated. This will remain illuminated until the transfer is done.

Parallel Mode Parallel mode is currently active. This will remain illuminated until the mode has been stopped.

Gen Management Generator Management is active. This will remain illuminated until the mode is stopped.

Emergency Mode A loss of utility power has occurred and the system has transferred or is in the process of transferring to generator power. This indicator light will remain illuminated until the system is back on utility power.

Load Shed Load has been shed due to a load shed condition on the Setup Add/Shed screen.

ATS Start This indicates if an ATS start signal is present. This will remain illuminated until the signal has been removed.

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7.3 HMI Status Screens

7.3.1 Status > LV Genset Summary

The LV Genset Summary screen displays mechanical and electrical metering for the selected generator.

Controls Description

Genset

Gen 1 Displays mechanical and electrical metering for generator 1.

Gen 2 Displays mechanical and electrical metering for generator 2.

Oil Press Generator set engine oil pressure in PSI.

Water Temp Engine water temperature in degrees F.

Batt Volt Engine starting battery voltage in DC Volts (VDC).

Eng Speed Engine speed in RPM.

Voltage (V) Output voltage across in AC Volts (VAC).

Current (A) Line current in amps.

Power Generator set output power in kilowatts (kW).

Freq Generator set output frequency in hertz (Hz).

Run Time Displays engine run time in hours.

% Loaded Displays generator load as a percent of rated kW.

Power Factor Displays generator set power factor output.

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7.3.2 Status > Utility

The Utility screen displays electrical metering for the selected utility.

Utility

Util 1 Displays electrical metering for utility 1.

Util 2 Displays electrical metering for utility 2.

Voltage (V) Displays voltage across the phases selected by the Voltmeter Switch control.

Current (A) Displays current for the line selected by the Ammeter Switch control.

Power Displays utility power in kW.

Freq Displays utility set output frequency.

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7.3.3 Status > PLC

The PLC screen displays the health of the PLCs and status of the system’s Modbus Plus and Modbus communication.

PLC

Run Indication Alternating green lights indicate that the PLC CPU is in Auto and is communicating to the HMI.

Heart Beat Counter The number will change to indicate that the CPU is running.

Modbus Plus

Modbus Plus Device Status

A green light indicates that the device is communicating. A red light indicates communication failure for the associated CPU.

DEC 550

Decision-Maker

550 Controller Status

A green light indicates that the associated generator set controller is communicating. A red light indicates communication failure for the associated controller.

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7.3.4 Status > LV Multi Gen

The Genset Multi Gen screen displays the mechanical and electrical data for all generator engines.

LV Multi-Gen Mechanical Metering

Oil Press (PSI) Displays generator set engine oil pressure in PSI.

Water Temp (F) Displays engine water (coolant) temperature in degrees F.

Batt Volt (VDC) Displays engine starting battery voltage in VDC.

Eng Speed (RPM) Displays engine speed in RPM.

Run Time (Hrs) Displays engine run time in hours.

LV Multi-Gen Electrical Metering

Voltage (V) Displays generator set output voltage.

Current (AMPS) Displays generator set output current.

Frequency (HZ) Displays generator set output frequency.

Power (kW) Displays generator set power in kW.

Power Factor Displays generator set power factor output.

% Loaded Displays generator load as a percent of rated kW.

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7.3.5 Status > ATS

ATS

ATS Indication Indicates the number of the ATS.

ATS Start Signal

Start Received Indicates an ATS start signal is present.

Source Availability

Normal Available Indicates the normal source is available for the ATS.

Emergency Available

Indicates the emergency source is available for the ATS.

Contactor Position

In Normal Indicates the ATS contactor is in the normal position.

In Emergency Indicates the ATS contactor is in the emergency position.

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7.4 HMI Control Screens

7.4.1 Control > LV Gensets

The Control Genset screen is used to control the selected generator. The user is able to run the generator, run without closing the breaker, leave the generator under automatic control of the PLC, or turn the generator off.

Master Start

Master Start Signal The master PLC is signaling the generator to run.

Shutdown Generator set has shut down because of a fault condition.

Warning Indicates an active fault condition that does not shut down the generator set.

DEC 550 NIA Controller master switch is not in the Auto position.

Gen Logic State Indicates current state of the PLCs engine sequencer state machine.

Reset

Reset Required Places the generator sync control logic in Automatic.

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Engine Control

Run/Closed Runs the generator and allows for the generator circuit breaker to close to the bus.

Run/Open Runs the generator but does not allow for the generator circuit breaker to close to the bus.

Auto Places the generator under the control of the PLC.

Off Prevents the generator from starting. If the generator was running, the generator will go into its cooldown cycle and then stop.

CD Control

Bypass Bypasses the Cooldown Delay timer and shuts down the generator set.

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7.4.2 Control > LV Tie

T1

Auto Places the circuit breaker under the control of the PLC. Close button is disabled.

Manual Disables automatic control of circuit breaker and enables the Close button.

Open Opens the circuit breaker and places the breaker control in Manual position.

Close Closes the circuit breaker if circuit breaker control is in Manual position.

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7.4.3 Control > LV Feeders

Emergency Mode Emergency Mode is active due to an ATS start signal which places the system on generator power.

No Load Test The generators are running due to an operator initiated No-Load Test start command. This will remain illuminated until the No-Load Test is manually stopped.

Load Shed Load has been shed due to a load shed condition on the Setup Add/Shed screen.

Gen Management Generator Management is active.

ATS Start This indicates if an ATS start signal is present.

F1, F2, F3, F4, F5, F6, F7, LB and PG

Auto Places the circuit breaker under the control of the PLC. Close button is disabled.

Manual Disables automatic control of circuit breaker and enables the Close button.

Open Opens the circuit breaker and places the breaker control in Manual position.

Close Closes the circuit breaker if circuit breaker control is in Manual position.

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7.4.4 Control > LV Gen Mgmt

Generator Management optimizes the number of on-line generator sets based on the kW requirement of the system load. The user will assign one of the generators as the lead unit. This generator will always be on-line. The generators after the lead unit will be assigned a priority. Higher priority units are sequenced on in the order of their priority and taken off in reverse priority. The generators soft load and unload.

Adjust Order Select the up or down arrow to change the generator order to the corresponding order desired. The Order column will always begin with 1, but the generator will move, depending on which arrow is selected. This order is used to remove generators off-line due to the system load demand. The generator with the highest order is taken off-line first, followed by the next highest generator order. (Note that this order is in effect only while the order selection method is in Manual.)

Order Selection Method

Runtime The order of the generators is determined by the generator runtime hours. The generator with the most runtime hours will be the first order. The generator with the least amount of runtime hours will be the last order.

Manual The order of the generators is determined by the operator. Use the Adjust Order column to change the order of the generators.

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Start

Start Gen

(% Load)

This setpoint is used in conjunction with the order to determine the load level at which to start the generator. The higher the order of the generator, the lower start load level. Once the system load is above the start level, the system will begin the Delay Before Start timer.

Delay before start (Sec)

Sets the length of time that the system kW level must be above the load level to start the generator and bring it on-line to the generator bus.

Stop

Stop Gen

(% Load)

This setpoint is used in conjunction with the order to determine the load level at which to stop the generator. The higher the order of the generator, the higher stop load level. Once the system load is below the stop level, the system will begin the Delay Before Stop timer.

Delay before stop (Min)

Sets the length of time that the system kW level must be below the load level to stop the generator and remove the generator off-line.

Control

Auto Select to enable Generator Management Mode. The system will not enter Generator Management Mode until the Stable Delay timer expires.

Off Select to turn off Generator Management Mode. If system was in Generator Management Mode and generators where shut down due to light load, they will restart and go back on-line.

Overload

Start Gen

(% Load)

Sets the percent above which the generators must be loaded before the system starts the Overload Start Time Delay.

Delay before start (Sec)

Sets the length of time that the generators must be loaded above the Overload % setpoint before the system starts all available generators.

Stable Delay

Delay after start (Min)

Sets the length of time the system must be on generator power with no generator shutdown or load shed conditions active before the system will enter Generator Management. (Generator Management control must be in Auto.)

Stable Delay Timer Indicates the amount of time before the system will enter Generator Management. Timer is active when it is blue.

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7.4.5 Control > Timed Test

LV Timed Load Test

Start Starts the Timed Test.

Stop Stops the Timed Test.

Test Time per Generator

Min Sets the duration of the test per generator.

Overlap Time Delay

Sec Sets the duration of overlap of generators for the time test.

Area Protection

On Turns on Area Protection for a specific ATS.

Off Turns off Area Protection for a specific ATS.

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7.4.6 Control > No Load Test

No Load Test

Start Starts the No Load Test.

Stop Stops the No Load Test.

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7.5 HMI Setup Screens

7.5.1 Setup > LV Add/Shed

Use the Setup Add/Shed screen to set the load shed setpoints and other criteria for load add and load shed.

Setpoints Description

Generator Bus Overload Shed

Enable Press to enable Overload Shed conditions.

Disabled Press to disable Overload Shed conditions.

Setpoint (% load) Sets the generator overload setpoint. Once the percent load of the on-line generator(s) is greater than this setpoint, the system will step load off sequentially (starting with the highest priority) until the percent load is less than this setpoint.

Delay (Sec) Sets the time delay in which the percent load of the on-line generators must be greater than or equal to this setpoint.

Engine Failure Shed

Enable Press to enable Engine Failure Shed conditions.

Disabled Press to disable Engine Failure Shed conditions.

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Generator Bus Underfrequency Load Shed

Setpoint (Hz) Sets the frequency level at which the Underfrequency Delay timer will start.

Once the timer expires, the system will issue an underfrequency load shed command.

Delay (Sec) Sets the time delay the system bus frequency must be below the underfrequency setpoint (Hz) before the system will issue an underfrequency load shed command.

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7.5.2 Setup > LV Relays

The generator protective relays are located in the Decision-Maker® 550 generator set controller. Change the relay setpoints using the touchscreen on the switchgear.

After changes to the setpoints are made, select the Save Changes button to write to the 550 controller.

Note: Changes made on the screen are not sent to the controller until the Save Changes button is selected.

After saving to the 550 controller, verify that the entered value equals the stored value.

Frequency

Over (81O)

Setpoint Set the overfrequency protection as a percent of the generator rated frequency.

The actual frequency is displayed for reference.

Time Delay The time delay sets the length of time that the measured value must remain over or under the setpoint before the relay activates.

Under (81O)

Setpoint Set the underfrequency protection as a percent of the generator rated frequency. The actual frequency is displayed for reference.

Time Delay For each setpoint, the time delay sets the length of time that the measured value must remain over or under the setpoint before the relay activates.

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Voltage

Over (59)

Setpoint Set the overvoltage protection as a percent of the generator rated voltage. The actual voltage is displayed for reference.

Time Delay The time delay sets the length of time that the measured value must remain over or under the setpoint before the relay activates.

Under (27)

Setpoint Set the undervoltage protection as a percent of the generator rated voltage. The actual voltage is displayed for reference.

Time Delay For each setpoint, the time delay sets the length of time that the measured value must remain over or under the setpoint before the relay activates.

Power

Over (32O)

Setpoint Set the reverse power and overpower protection as a percent of the generator rated kW. The actual kW is displayed for reference.

Time Delay The time delay sets the length of time that the measured value must remain over or under the setpoint before the relay activates.

Rev (32R)

Setpoint Set the reverse power and overpower protection as a percent of the generator rated kW. The actual kW is displayed for reference.

Time Delay The time delay sets the length of time that the measured value must remain over or under the setpoint before the relay activates.

kVARS

Rev (40)

Setpoint Set loss of field protection for paralleled generators. The relay is set as a percent of the generator rated kVAR. The actual setpoint is displayed for reference.

Time Delay The time delay sets the length of time that the measured value must remain over or under the setpoint before the relay activates.

Current

Over (51)

Setpoint Set the overcurrent protection as a percent of the generator rated current. The actual setpoint is displayed for reference.

Time Delay The time delay sets the length of time that the measured value must remain over or under the setpoint before the relay…