Quick Start Guide for Auto Paralleling{4450, 7451} Caterpillar

Quick Start Guide for Auto Paralleling{4450, 7451}

Usage:

Engine:: 3516C (S/N: KEN1-UP)

Introduction

This special instruction is a Quick Start Guide to be used in order to clarify the quick start method for the Auto Paralleling units in the field.

Single Unit

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Illustration 1	g01951599

Prior to running:

Make lead unit jumper selection to enable dead bus closure. Located at terminal strip on street side.

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Illustration 2	g01951615

Application Notes:

In single unit mode, the paralleling controller and Basler protective relay can be switched off if desired. The unit will operate similar to a standard gen set. This switch is located behind the EMCP3 near the terminal switch.

Island Mode

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Illustration 3	g01951602

Prior to running:

Make lead unit jumper selection to enable dead bus closure on ONE UNIT ONLY and interconnect signal wiring (load share line, VAR share line-if applicable, lead-unit-select wiring) between units. Located at terminal strip on street side.

Application Notes:

In island mode, GPC (paralleling controller) performs real (kW) and reactive (kVar) load sharing with like units using independent load sharing analog signals. GPC is backwards compatible with legacy units for real power (kW) sharing.
Reactive (kVar) load sharing should be disabled when paralleling with legacy units. The factory default setting in the GPC is set to "disabled".

Utility Parallel

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Illustration 4	g01951603

Prior to running:

Interconnect wiring to utility breaker auxiliary contact. Generator control system automatically detects utility parallel mode when the utility breaker auxiliary contact is closed.
Verify lead jumper is NOT INSTALLED.
Verify load share lines are NOT interconnected with other units.
Verify GPC is programmed to the desired Baseload level (default is 1825kW)
Verify GPC is programmed to the desired Ramp rate (default is 10kW/sec.)
Verify GPC is programmed to the desired PF control (default is i0.95)

Application Notes:

In utility parallel mode, Basler protective relay will perform sync-check to permit generator breaker closure and protects system from faults when in parallel.
UMR reset: TRIP is reset by pressing STOP on EMCP3 (with 86 lockout relay in tripped state). MAJOR ALARM (indicating fuse loss) is reset by pressing RESET on UMR.
Baseload level is controlled by either the Baseload potentiometer or pre-programmed setpoint in the GPC. Selection is made by a two-position switch.

EMCP3 Control

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Illustration 5	g01951605

Note: Refer to EMCP3 info film for start/stop instructions.

RUN Mode

In RUN mode, operator must close breaker using breaker control switch (when running at normal voltage and normal frequency). Manual voltage adjust is allowed.

Auto Mode

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Illustration 6	g01951607
Local Start/Stop Switch

In AUTO mode, breaker will automatically close (when running at normal voltage and normal frequency). GPC automatically adjusts voltage and frequency.

STOP

Pressing STOP:

"Single Unit" and "Island modes" - Breaker will open immediately and engine goes into cooldown.

"Utility modes" - Generator load will ramp down to 10 percent (of rated), the breaker will then trip open and engine goes into cooldown.

General Notes

Remote run request signal can be disabled, if desired, with jumper removal (jumper installed as default).
Generator breaker can be locked out using the breaker control switch pull-to-lock feature.
Reset the 86 lockout relay by first pressing "STOP" on EMCP3.

Generator Paralleling Controller (GPC)

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Illustration 7	g01951520

"AUTO" lamp - This LED is lit when any of the conditions below are present.
- Controller is performing auto synchronization (breaker is open). EMCP3.3 must be in auto mode and the voltage and the frequency built up to normal.
- Generator breaker is closed in either "SINGLE UNIT" or "ISLAND MODE".
- Generator breaker is closed with request to run active "UTILITY PARALLEL MODE". Lamp goes off during ramp-down when unit is stopping.

"ACTIVE" lamp - This LED is lit when not in setpoint programming mode using the keypad.
Note: Does not indicate whether or not setpoint programming is in use by the PC interface.

"CB CLOSE CMD" lamp - This LED is lit when the controller is issuing a circuit breaker close signal.
Note: This will occur only when the LED synchroscope had the green LED lit (center position).

"Hz−, Hz+" lamps - These two lamps indicate when the controller is actively biasing the speed signal to the engine control (Hz− is decreasing speed, Hz+ is increasing speed). When paralleled with other sources, indicates decreasing or increasing generator real load (kW) contribution.
"V-, V+ lamps" - These two lamps indicate when the controller is actively biasing the voltage regulator (V- is decreasing voltage, V+ is increasing voltage). When paralleled with other sources, indicates decreasing or increasing generator reactive (VAR) contribution.

LED synchroscope row of lamps - When the lights are moving left to right, the generator is moving faster than the bus. When the lights are moving right to left, the generator is moving slower than the bus. The synchroscope is only active when voltage is within 50% to 125% rated and frequency is within ± 2Hz. When the green LED (center position) is lit then the generator is "in sync" with the bus.

"GEN CB CLOSED" lamp - This LED is lit when the generator breaker is closed.

DISPLAY / SELECT pushbutton -
When the "ACTIVE" lamp is lit, pressing this button (DISPLAY) will alternate between two AC metering screens:
- One shows generator and bus the voltage and the frequency
- The other shows generator voltage, current, kW, and PF ("i" indicates leading/inductive, "k" indicates lagging/capacitive).
When the" ACTIVE" lamp is off, pressing this button (SELECT) will apply setpoint changes made using the other buttons and advance through the setpoints menu.

"DIGIT" pushbutton - This button is used only when programming setpoints (ACTIVE lamp off). When pressing this button, the number at which the cursor is currently located is increased by one digit.

CLEAR / CURSOR pushbutton -
When the" ACTIVE" lamp is lit, pressing this button will clear controller alarms.
When the "ACTIVE" lamp is off, pressing this button will move the cursor to the desired setpoint digit.

Press "DIGIT" and "CLEAR / CURSOR" pushbuttons simultaneously to enter/exit setpoint programming mode.

Press "DISPLAY / SELECT" and "CLEAR / CURSOR" pushbuttons simultaneously to move back in the setpoints menu.

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Illustration 8	g01951523

"Utility Transfer Trip" lamp - This LED is lit when the customers utility transfer trip signal is present.

"Utility Breaker" lamp - This LED is lit when the utility breaker is closed.
Note: When this LED is lit and the Red LED on the breaker control switch (4) is lit, then the generator is operating in parallel with the utility source.

86 Lockout Relay - This device performs fast response fault clearance by opening the generator breaker directly and placing the engine in cooldown when a fault occurs as detected by the on-package Basler protective relay or customer's utility transfer trip signal.
Note: The EMCP3 must be in "OFF" mode to allow the manual reset of the 86 lockout relay (this also resets fault alarms in the Basler relay).

Circuit Breaker Switch - For automatic paralleling modes, this switch must be in the center position (red or green flag). For manual paralleling modes, the generator breaker is signaled to close when this switch is held in the "close" position and paralleling conditions are satisfied. This switch also provides a "pull-to-lock" feature that gives a constant trip signal to the breaker to lockout operation. Breaker status is indicated by the LEDs on the switch. The green means open. The red means closed.

"Dead Bus Close Permissive" lamp:
Single Unit Mode - lamp is ON when the lead unit jumper is installed and goes OFF when the breaker closes
Utility Parallel Mode - This lamp should never be ON in this mode. If it is, then remove the lead unit jumper.
Island Mode - The lamp is ON when all units are in standby and at least one unit has the lead unit jumper installed. When units are started this lamp turns OFF on all except the unit with the lead unit jumper. If that unit fails to close, the permissive signal will transfer to the next unit and this lamp will come ON in that unit. This lamp goes OFF when any unit is closed to the bus.
Note: In Island Mode, If all are not ON then inspect the interconnect wiring

"Auto Start" lamp - This LED is lit when either a remote run request is present or the local auto start switch is in the run position.
Verify the status of this lamp before placing the EMCP3 in auto mode. If this lamp is ON then the unit will start once the EMCP3 is placed in automatic.

Baseload potentiometer - This potentiometer is used to manually adjust the generator kW output (range of 400kW to 1825kW) when in parallel with the utility. This potentiometer is enabled by the left position of the switch (8) below it .

Baseload Select Switch - With this switch in the left position, potentiometer (7) is used for baseload level reference. In the right position the setpoint in the GPC "Power Controller P set1" provides the baseload level reference.