EMCP II P Application Notes Rev 10

EMCP II+P Application Notes rev 1.0.
doc
APPLICATION NOTES
FOR PARALLELING CONTROL PANEL
ELECTRIC POWER DIVISION
Caterpillar: Confidential Green
Page 1 of 13
Updated: 11/29/07
EMCP II+P Application Notes rev 1.0.doc
Introduction ....................................................................................................3 1.1 Overview.................................................................................................3 2 Applications ...................................................................................................4 2.1 Continuous Duty (Prime Power) .............................................................4 2.2 Standby Duty (Isolated from Utility) ........................................................4 3 Paralleling Modes of Operation......................................................................5 3.1 Manual Permissive Paralleling................................................................5 3.2 Automatic Paralleling ..............................................................................6 4 System Interface............................................................................................6 4.1 Start Signal .............................................................................................6 4.2 Best Battery ............................................................................................6 5 Load Control Functions..................................................................................6 5.1 Generator Set Based Load Shed............................................................6 5.2 Load Add ................................................................................................7 5.3 Load Sense Demand ..............................................................................7 6 Paralleling Control Panel ...............................................................................7 6.1 General...................................................................................................7 6.2 Displays ..................................................................................................7 6.3 Operator Controls ...................................................................................8 6.4 Generator Metering ..............................................................................11 6.5 Generator Protective Relaying..............................................................11 6.6 Bus Metering ........................................................................................11 7 Paralleling Functions ...................................................................................12 7.1 kW Sharing ...........................................................................................12 7.2 VAR Sharing.........................................................................................12 8 Programming Considerations ......................................................................12 9 Optional Modules.........................................................................................12 9.1 CCM .....................................................................................................12 10 Design Considerations .............................................................................13 10.1 NFPA 110 .............................................................................................13 10.2 Generator Set Performance..................................................................13 10.3 Paralleling multiple C32 systems..........................................................13 10.4 Forwards / Backwards compatibility .....................................................13 11 Useful References....................................................................................13
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1 Introduction
1.1 Overview
This document describes the operation and implementation of the EMCP II+P paralleling control panel on the C32 genset platform. The EMCP II+P control panel is intended for use with two (2) C32 package generator sets with package mounted electrically operated circuit breakers. The generator sets will operated in either a continuous (prime power) application, or in an automatic standby application with the addition of an automatic transfer switch. The EMCP II+P provides a simple, low cost solution to synchronizing and paralleling when complex controls are not required. The EMCP II+P control panel provides automatic synchronizing and isochronous load sharing, all within the genset mounted panel. With the package mounted electrically operated circuit breaker, the panel will provide a complete paralleling solution. The Generator Set Control (GSC+P) is capable of synchronizing in two modes: Manual (Permissive) and Automatic. The GSC+P acts as an automatic speed matching synchronizer, synch-check relay, and synchroscope to insure that the unit is safely synchronized in all modes of operation. The GSC+P also includes all of the protective relaying functions found in the EMCP II+, including over/under voltage, over/under frequency, and reverse power to properly protect the unit during paralleling. Isochronous load sharing is accomplished via a standard load share module. The GSC+P also includes full power metering allowing the unit to be monitored for proper engine and generator loading. The EMCP II+P is configured from the factory for synchronizing and paralleling two (2) C32 package generator sets, isolated from the utility. The EMCP II+P is not a utility paralleling controller, and should not be used to parallel with a utility source. For utility paralleling applications, consider using traditional switchgear. By reviewing the information below you should better understand the capabilities and limitations of the EMCP II+P panel and its role in the synchronizing and paralleling of generator sets. This document is intended to be used in conjunction with the control panel schematics (303-2360) and the EMCP II+P Systems Operation Troubleshooting, Testing, and Adjust (KENR8601).
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2 Applications
2.1 Continuous Duty (Prime Power)
Sequence of Operation
In a continuous, or prime power application, the generator sets act as the only source of power for the site. At initial start up, both generator sets are started and allowed to reach rated speed and voltage. As the first unit reaches rated speed, its generator circuit breaker closes, powering the load bus. Dead bus logic shall prevent the two units from simultaneously closing to the dead bus. The second generator set will then synchronize to the live bus, and close its breaker once synchronization conditions are met. Once the system is stable, the units shall equally share site load. Basic load shed function shall be provided to prevent overload of a generator set upon loss of a single generator set.
2.2
Standby Duty (Isolated from Utility)
Sequence of Operation
For standby duty, a transfer switch or other similar device is required to detect loss of utility, transfer load from a failed utility source, and ensure separation of utility and generator sources.
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EMCP II+P Application Notes rev 1.0.doc The ATS (or other similar device) detects loss of utility and will send a system start signal to the generator sets. Both generator sets start, attain rated speed and voltage, and the first unit up to rated voltage and frequency closes to the dead bus. Logic is included to prevent both units from simultaneously closing to the dead bus. The second unit will then synchronize to the live bus and closes its circuit breaker. Once the system is stable, the units shall equally share site load. Basic load shed function are provided to prevent overload of the remaining generator set upon loss of a single generator set. Upon return of utility, the transfer switch (or other similar device) will initiate a return to utility, remove the remote start command, and the generator sets will be placed in cooldown.
3 Paralleling Modes of Operation

3.1 Manual Permissive Paralleling
This paralleling mode is entered when the synchronizing switch is in the MANUAL position and the engine control switch is in MANUAL. Generator set frequency is not automatically controlled, and should be adjusted from speed adjust potentiometer located at the EMCP II+P control panel. The operator manually initiates a circuit breaker close command, and the paralleling control panel permits circuit breaker close once synchronization conditions are met. Dead bus arbitration will not be active during this mode of operation. It will be the operators responsibility to only close one unit to the dead bus.
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3.2
Automatic Paralleling
This paralleling mode is entered when the synchronizing mode select is in the AUTO position, the engine control switch is in AUTO, and a remote start signal is received. Automatic synchronization is not available when the engine control switch is placed in MANUAL run mode. Generator set frequency is automatically controlled by the EMCP II+P panel. When synchronization conditions are met, the EMCP II+P initiates a circuit breaker close command. Dead bus arbitration will be active during this mode of operation to prevent simultaneous closing of both generator sets to the dead bus.
4 System Interface
4.1 Start Signal
The EMCP II+P is designed with the ability to have a single remote start contact (normally open, close to run) control both generator sets simultaneously. To enable this feature, add an interconnect wire between terminal 72 in both generator sets. Then wire the remote start contact between terminal 72 and 73 in one of the generator sets for single point remote start control.
4.2
Best Battery
The EMCP II+P is also equipped with a simple best battery circuit to provide +24VDC power for system level functions, such as single point remote start, load shed, and load add functions. To enable this feature, add an interconnect wire between terminal 73 in each generator set.
5 Load Control Functions

A four pole relay (designated as the Load Shed Relay, or LSR on the drawings) is provided in each generator set for customer use to enable simple load shed / load add capability. The relay has four (4) form C dry contacts rated for 10A, 24VDC / 120VAC to indicate the position of the generator circuit breaker. These contact can be wired together on site for basic stage 1 and stage 2 load control capability, as described below.
5.1
Generator Set Based Load Shed
The contacts from the load control relay on each generator set can be used to shed priority loads upon loss of a generator set. For a stage 1 load shed (loss of a single generator set), a contact from each generator set should be wired in series to the load shed input or shunt trip device at the load.
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5.2
Load Add
The contacts from the load control relay on each generator set can be used to add loads based on generator set capacity. For a two stage load add strategy, wire the load add contacts in parallel for the stage one (critical) loads that will be powered once the first generator set is on line. Wire the contacts in series for stage 2 (noncritical) loads to be powered after both generator sets are on line.
5.3
Load Sense Demand
Load sense demand functions to maintain the correct number of generator sets on line for the site load is not available with the EMCP II+P control panel.
6 Paralleling Control Panel

6.1 General
The EMCP II+P controller consists of an operator interface panel, customer connection section, and AC control section. These sections are incorporated as an integral part of the generator terminal box.
6.2
Displays
6.2.1 Synchronizing Mode

Voltage and Frequency The EMCP II+P displays the voltage and frequency of both the bus and the generator. The top display will alternate between displaying the voltage and frequency of the bus and generator. The word bus or gen appears in the right side window to indicate which parameter is being displayed. In Automatic Sync Mode, two seconds after the breaker closes the top display will return to the normal mode, displaying voltage, current, and frequency information for the generator only. Synchroscope When a synchronization mode is selected, the EMCP II+P displays the synchroscope on the bottom GSC+P display. This unique display allows a simultaneous visual indication of both frequency and phase of the generator set, in reference to the bus. The display will indicate whether the generator needs to speed up or slow down relative to the bus. When the generator set is synchronized with the bus the sychroscope provide visual indication. For Automatic Sync mode, two seconds after the breaker closes the bottom display will return to the normal mode, displaying power meter information on the left and engine information on the right for the generator set.
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EMCP II+P Application Notes rev 1.0.doc If the GSC+P detects that the generator and bus phase sequences do not match, the synchroscope display will alternately flash brackets on the left and right sides of the display. Upon entering a synchronization mode, if the GSC+P detects that there is no bus voltage (a dead bus), the synchroscope outline will flash in unison with the three spare LEDs. Once the breaker has closed to the dead bus, the display will return to its normal operation.
6.2.2 Displays (Normal Operation)

Voltage, Current, and Frequency During normal operation (non-synchronizing mode) the upper display has seven different screens of information which can be scrolled through. Each of these screens shows different AC metering information including generator voltage (line-to-line, line-neutral, or average), generator current (per phase and total) and generator frequency. Power Metering During normal operation (non-synchronizing mode) the left hand side of the lower display provides power metering information about the generator set. There are 13 different parameters available for viewing including real power - kW (total and per phase), apparent power kVA (total), reactive power kVAR (total), percent of rated power (%kW), power factor (average and per phase), total energy output kWHr, and total reactive energy output kVARHr. This power meter information can be used to insure that the engine is loaded properly, providing the proper amount of real power based upon its rating and insure that reactive power is being shared equally by all units, insuring that the generator is not overloaded. Engine Information During normal operation (non-synchronizing mode) the right hand side of the lower display provides engine and system related information about the generator set. Information that can be found includes engine oil pressure, engine coolant temperature, engine speed (RPM), system battery voltage, and engine operating hours.
6.3
Operator Controls
6.3.1 Engine Control Switch

The engine control switch (ECS) switch is manually operated and has four positions: OFF/RESET The OFF/RESET position is used for normal stopping of the engine. When the unit is running, turning the ECS to the OFF/RESET position will cause the engine to stop immediately. It is also used to reset any active faults on the GSC+P, ADEM, or CDVR.
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EMCP II+P Application Notes rev 1.0.doc AUTO The AUTO position is used for automatic starting systems. It requires that a remote start signal be wired to GSC+P. When the remote start signal is present the unit will automatically start and run. Once the remote start signal is removed the unit will continue to operate for the programmed cooldown time (adjustable from 0 to 30 minutes) before stopping. MAN/STOP The MANUAL position is used to start the unit locally. COOLDOWN/STOP - While the unit is running, turning the ECS to the COOLDOWN/STOP position will cause the engine to run for the programmed cooldown time (adjustable from 0 to 30 minutes) before stopping.
6.3.2 Emergency Stop Pushbutton

Mushroom head, twist to reset, causes engine shutdown and tripping of the generator circuit breaker. Prevents engine starting when depressed.
6.3.3 Speed Adjust

A 10K potentiometer provides a small adjustment range for the generator speed (frequency). Turning the potentiometer to the right will cause an increase in the generator speed. Turning the potentiometer to the left will cause a decrease in the generator speed. This adjustment may be necessary when manually synchronizing the generator to the bus.
6.3.4 Voltage Adjust

A three position, spring return to center switch provides a small adjustment range for the generator output voltage. The VOLTAGE RAISE position will cause an increase in the generator voltage. The VOLTAGE LOWER position will cause a decrease in the generator voltage. This adjustment may be necessary when manually synchronizing the generator to the bus.
6.3.5 Synchronizing Select Switch

Three (3) position switch. Switch positions shall be used to select paralleling mode and will be: MANUAL OFF AUTO. See Section 3 for detail description of paralleling modes.
6.3.6 Circuit Breaker Close Pushbutton

When the generator is being paralleled manually, the breaker close push button must be pressed by the operator to close the breaker. The system does not allow the breaker to close unless all of the synchronization parameters have been met. When the breaker is closed (generator online) the indicator will light (red in color) continuously.
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6.3.7 Circuit Breaker Open Pushbutton

When the generator is being taken off-line manually, the breaker open pushbutton must be pressed by the operator to open the breaker. When the breaker is open and the engine is running, the indicator will light (green in color) continuously.
6.3.8 Annunciator Module

A NFPA-110 annunciator module will be provided as standard. Includes flashing LED warnings for: low coolant temperature, high coolant temperature (pre-alarm), low oil pressure (pre-alarm), engine control switch not in automatic, and low DC voltage. Includes alarm horn and acknowledge push-button. In addition, a custom alarm module (CAM) will be provided to annunciate additional paralleling functions, such as: CDVR fault, CDVR alarm, and fail to parallel.
6.3.9 Spare Indicators Synchronizing Mode

The spare indicators are used during the synchronizing process as a redundant sync check. During the synchronizing process, before the breaker is closed, the lamps will indicate whether the generator is in sync with the bus. The three indicators are: Generator Voltage Match The voltage match LED will light continuously only if the voltage window is less than the programmed window. The voltage match window is adjustable from 1 to 15%. The generator voltage level can be adjusted manually from the front of the EMCP. This potentiometer adjusts the voltage regulator excitation, thereby controlling the voltage output. Generator Frequency Match The generator frequency match LED will light continuously only if the frequency match conditions have been met. The allowable frequency difference between the bus and generator is defined by two programmable parameters within the GSC+P: synchronizing dwell time and the phase angle limit. The allowable frequency difference varies inversely with dwell time and directly with phase angle limit. Using the setpoints for these two parameters, the maximum frequency difference possible is 1.1 Hz. Given the default values for these setpoints, the frequency difference is about 0.5 Hz. The maximum allowable frequency difference is 1.1 Hz but with the factory settings for dwell time and phase angle the allowable frequency difference is limited to .05 Hz. (Cut the part about the speed matching, since it is really the phase matching covered in the next bullet). Generator Phase Match The generator phase match LED will light continuously only if the phase difference between the bus and
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EMCP II+P Application Notes rev 1.0.doc generator is less than the programmed limit. The phase angle limit is adjustable between 1 and 25 degrees. If the generator parameters are not matched to the bus, the associated lamp will flash. When the generator and bus voltage, frequency, and phase are in sync, the lamps light continuously. (When not in the synchronizing mode, the same three spare indicators are customer programmable.) If a Shutdown fault occurs during any synchronization process, the EMCP II+P will enter its Shutdown mode and all spare LEDs will return to their customer-programmed functions.
6.4
Generator Metering
Generator metering shall be provided from the standard EMCP II+P control panel and include the following: Generator AC Voltage 3 Phase (L-L and L-N) Generator AC Current (per phase and average) Generator Power (kW, kVAR, kVA) (total and per phase) Generator % of rated power (total) (kW, kVA, kVAR) Generator Power Factor (average and per phase)
6.5
Generator Protective Relaying
Generator protective relaying shall be provided by the standard EMCP II+P control panel and include the following: Over/Under voltage (27/57) Over/Under frequency (81 o/u) Reverse power (32)
In addition to the EMCP II+P protective relays, the following shall also be provided from the CDVR: Overexcitation Overcurrent (51) protection shall be provided by the package mounted circuit breaker.
6.6
Bus Metering
When the GSC+P is performing synchronization functions, the top display of the GSC+P will toggle between the bus and generator phase C-A voltage and frequency. The right side of the display will show bUS or GEn.
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7 Paralleling Functions
7.1 kW Sharing
To ensure proper sharing of kW between generator sets, load share modules (part number 309-1583) are installed as standard on each generator set. For more information, refer to the Generator Set Load Sensing and Load Sharing Module SOTA (RENR2471).
7.2
VAR Sharing
To ensure proper sharing of VARS between generator sets, the voltage regulators will need to be wired in cross current compensation mode. For more information, refer to CDVR Specifications Systems Operation Testing and Adjusting (RENR7941).
8 Programming Considerations
The EMCP II+P offers flexibility for matching the operation of the unit to the specific site requirements. There are many programmable setpoints within the GSC+P which can be adjusted to optimize the performance of the unit during synchronizing and paralleling. The following setpoints and functions should be reviewed during the commissioning of the unit to insure proper operation: Protective Relaying Setpoints (OP5-2) There are 42 setpoints, which control the operation of the various protective relaying alarms and shutdowns. Each of the parameters should be reviewed and optimized based upon the specific sight conditions. Paralleling Programming (OP5-3) There are 14 different setpoints that control the operation of the synchronizing process. Each of these parameters should be reviewed and adjusted based upon the site conditions.
9 Optional Modules
9.1 CCM
The EMCP II+P is not equipped with a communication port for customer use as a standard feature. To communicate to the EMCP II+P from a remote PC, a Customer Communication Module (CCM) is required. For more information on the CCM, refer to the Operation and Maintenance Manual for CCM, SEBU6874.
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10 Design Considerations
10.1 NFPA 110
The C32 with EMCP II+P is suitable for use in NFPA110, or other critical load applications if standard design practices are used. When installed in a critical application, such as a site with emergency standby loads, ensure that the critical loads are less than what one generator set can accept in a single load step. Wire the load add circuit as described in Section 5.2 to add load as soon as the first generator sets circuit breaker closes. This will enable the critical load to be powered as soon as one of the two generator sets reaches rated speed.
10.2 Generator Set Performance

The EMCP II+P will not impact the basic C32 generator set performance. All performance parameters, such as starting, transient response, emissions, fuel consumption, air flow, will not be impacted by replacement of the EMCP 3 controls with the EMCP II+P controls.
10.3 Paralleling multiple C32 systems

The EMCP II+P is configured to parallel two (2) generator sets to for a single system. While the load share and cross current strategies have been used on more than two generator sets, paralleling more than two (2) generator sets is not supported as a factory option.
10.4 Forwards / Backwards compatibility

The EMCP II+P implementation on the C32 generator set is designed as a dedicated purpose control panel to allow for paralleling of two (2) C32 package generator sets. The EMCP II+P cannot be easily added to a new site that requires more that two generator sets. For a site with existing paralleling controls, such as floor standing switchgear or an on package paralleling solution, the EMCP II+P should not be considered as a prime option, and instead the existing paralleling control strategy should be used. As Caterpillar continues to develop the next generation of paralleling controllers, these new controllers will not be compatible with the EMCP II+P. If a site is installed with the EMCP II+P, and the customer would like to upgrade to the new paralleling control panel, this will require all new control panels, controls, and harnessing. If future site expansion may be required, consider offering a more traditional paralleling approach.
11 Useful References
Schematics Wiring Diagram EMCP II+P SOTA 306-0359 306-0359 KENR8601
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Updated: 11/29/07

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Caterpillar: Confidential Green