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Heinzmann Theseus AT 01 Manual

Analogue generator power controller and synchronizer
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Analogue Generator Power Controller
Copyright 2004 by Heinzmann GmbH & Co KG. All rights reserved. This document may not be reproduced or handed on to third parties.
HEINZMANN
Electronic Speed Governors
and Synchronizer
THESEUS AT 01
Heinzmann GmbH & Co. KG
Engine & Turbine Controls
Am Haselbach 1
D-79677 Schönau (Schwarzwald)
Germany
Phone
+49 7673 8208-0
Fax
+49 7673 8208-188
E-mail
info@heinzmann.com
www.heinzmann.com
V.A.T. No.:
DE145551926
®
Manual E 98 004-e / 08-06

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  • Page 1 Electronic Speed Governors Analogue Generator Power Controller and Synchronizer THESEUS AT 01 Copyright 2004 by Heinzmann GmbH & Co KG. All rights reserved. This document may not be reproduced or handed on to third parties. Manual E 98 004-e / 08-06...
  • Page 2 Practice all plant and safety instructions and precautions. Warning Failure to follow instructions may result in personal injury and/or damage to property. HEINZMANN will refuse all liability for injury or damage which results from not following instructions Danger Please note before commissioning the installation:...
  • Page 3 HEINZMANN have been advised of a particular purpose and even if a particular purpose is indicated in the manual. HEINZMANN also disclaim all liability for direct, indirect, incidental or consequential damages that result from any use of the examples, data, or other information contained in this manual.

  • Page 5: Table Of Contents

    Contents Contents Page 1 Safety Instructions and Related Symbols ................1 1.1 Basic Safety Measures for Normal Operation..............2 1.2 Basic Safety Measures for Servicing and Maintenance ..........2 1.3 Before Putting an Installation into Service after Maintenance and Repair Works ..3 2 Application..........................
  • Page 6 Contents 8 Commissioning ........................20 8.1 Mean and Position of Adjusting Potentiometers and Testpoints ........20 8.2 Mean and Position of LED’s ..................22 8.3 Initial Setting Up Procedure ..................24 8.4 Initial Setting of the Speed Governor................24 8.5 Adjustment of Synchronizer Device ................25 8.6 Adjustment of Load Sharing Device in Island Parallel Operation ........

  • Page 7: Safety Instructions And Related Symbols

    1 Safety Instructions and Related Symbols 1 Safety Instructions and Related Symbols This publication offers wherever necessary practical safety instructions to indicate inevitable residual risks when operating the engine. These residual risks imply dangers to persons product and engine environment. The symbols used in this publication are in the first place intended to direct your attention to the safety instructions! This symbol is to indicate that there may exist dangers to the engine, to...

  • Page 8: Basic Safety Measures For Normal Operation

    1 Safety Instructions and Related Symbols In this publication the Table of Contents is preceded by diverse instructions that among other things serve to ensure safety of operation. It is absolutely imperative that these hints be read and understood before commissioning or servicing the installation.

  • Page 9: Before Putting An Installation Into Service After Maintenance And Repair Works

    1 Safety Instructions and Related Symbols • Never use a water hose to clean cabinets or other casings of electric equipment! 1.3 Before Putting an Installation into Service after Maintenance and Repair Works • Check on all slackened screw connections to have been tightened again! •...

  • Page 10: Application

    2 Application 2.1 General The analogue generator power controller and synchronizer THESEUS AT 01 has been designed to work in conjunction with any of the HEINZMANN analogue electronic governors to make a complete generator management. It can also be used with competitors' electronic governors by the addition of a small interface card.

  • Page 11: Load Ramp Device

    2 Application 2.4 Load Ramp Device This facility allows a genset to soft load after closing the generator breaker without the island frequency deviating from the isochronous value. The load ramp is fully adjustable and will allow an engine to load from zero to the rated load on the load share line and unload down to either zero or a base load value.

  • Page 12: Block Diagram

    3 Block Diagram 3 Block Diagram Generator voltages Generator currents Bus / mains Figure 1: Block Diagram of Analogue THESEUS AT 01 THESEUS Analogue AT 01...

  • Page 13: Mode Of Operation

    4 Mode of Operation 4 Mode of Operation 4.1 General Referring to the AT 01 block diagram, there are three sections incorporating load sharing, synchronising and load ramping; these can be used independently of each other or in combination. The connection to the voltage and current inputs are made directly to the alternator outputs and require a three wire, three phase signal with appropriate current transformer inputs which can be specified to 1 A or 5 A CTs.

  • Page 14: Synchronizer Device

    4 Mode of Operation 4.3 Synchronizer Device The auto synchronizer incorporates three phase voltage inputs which are conditioned and compared for frequency and phase alignment. The unit first compares the frequency of the BUS to the generator and gives an output signal to the governor speed that automatically aligns the frequency.

  • Page 15: Technical Data

    5 Technical Data 5 Technical Data 5.1 General 3 x 110 V or 415 V AC ± 10% Input voltage phase to phase Input current 0 - 5 A per phase max. 2 VA 0 - 1 A per phase max. 2 VA select by resistor change Current consuption 400 mA...

  • Page 16: Synchronizer Device

    5 Technical Data Mains breaker closure LED indication 5.3 Synchronizer Device Contact load of synchronizer relay 30 V DC, 2.5 A ±1 up to ±15°, adjustable Phase angle Synchronizer time 3 up to 15 sec. depends on plant, adjustable Gain adjustable ±4 V Output signal...

  • Page 17: Electrical Connection

    6 Electrical Connection 6 Electrical Connection 6.1 Table of Terminal Connections and their Functions Terminal Function 0 V supply voltage +24 V supply voltage screen of lines on terminals 4, 5 and 6, 7 signal synchronizer output to governor 0 V synchronizer output to governor signal load sharing output to digital governor signal load sharing output to analogue governor 0 V load sharing output to governor...
  • Page 18 6 Electrical Connection Terminal Function switch input for base load close = on open = off switch input to ramp up / down close = up open = down switch input for synchronizer close = off +12 V via 100 Ohm open = on output for island / group synchronization synchronizer relay inhibit...

  • Page 19: Connection Of Bus Voltages And Current Transformers

    6 Electrical Connection 6.2 Connection of Bus Voltages and Current Transformers Generator AT 01 Earth Generator voltage Generator current Generator breaker Earth voltage L1 L2 L3 Attention: Take care that the right connections are made to the high voltage phases on the AT 01! The connections are shown as a generator power control with synchronizer application.

  • Page 20: Connection With Control Unit Of Series E 1 - F And E 2 - F

    6 Electrical Connection 6.3 Connection with Control Unit of Series E 1 - F and E 2 - F AT 01 KG 1-F/KG 2-F Terminal Accessory 4 5 6 Strip Plug Cable 3 x 0,5 mm² with shielding max. lenght 50 m Shielding connected at control unit only Figure 3: Connection with Control Unit of Series E 1 - F and E 2 - F 6.4 Connection with Control Unit of Series E 6 up to E 40...

  • Page 21: Connection With Control Unit Of Series E 2000

    6 Electrical Connection 6.5 Connection with Control Unit of Series E 2000 AT 01 KG 2000 Terminal Terminal 4 5 6 10 1114 Strip Strip Cable 3 x 0,5 mm² with shielding max. lenght 50 m Shielding connected at control unit only Figure 5: Connection with Control Unit of Series E 2000 6.6 Connection to more THESEUS Units AT 01 in Parallel Operation Figure 6: Connection to more THESEUS Units AT 01...

  • Page 22: Connection Of Load Setpoint Potentiometer In Parallel Mains Operation

    6 Electrical Connection 6.7 Connection of Load Setpoint Potentiometer in Parallel Mains Operation Load setpoint Unit from plant 1 potentiometer 10 KOhm AT 01 Max. 5 KOhm 1610 Min. Auxiliary contact mains breaker Both cables 3 x 0,5 mm² with shielding to further plants Shielding connected at one side only Figure 7: Connection of Load Setpoint Potentiometer...

  • Page 23: Connection Of External Base Load

    6 Electrical Connection 6.9 Connection of External Base Load AT 01 Terminal 22 23 24 25 Strip Max. Min. 5 KOhm Cable 3 x 0,5 mm² with shielding Figure 9: Connection of External Base Load 6.10 Connection of External Load Limitation AT 01 Terminal 39 40...

  • Page 24: Connection Of External Droop, If Necessary

    6 Electrical Connection 6.11 Connection of External Droop, if necessary AT 01 Terminal 20 21 Strip Max. 20 KOhm Min. 0 Ohm = max. droop 20 K Ohm = min. droop 0,5 % open = isochronus Figure 11: Connection of External Droop THESEUS Analogue AT 01...

  • Page 25: Measurement

    5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Figure 12: Measurement of Analogue THESEUS AT 01...

  • Page 26: Commissioning

    8 Commissioning 8 Commissioning 8.1 Mean and Position of Adjusting Potentiometers and Testpoints Figure 13: Position of Adjusting Potentiometers and Testpoints THESEUS Analogue AT 01...
  • Page 27 8 Commissioning Potentiometer Function gain- adjustment for closed loop of synchronizer unit stability- adjustment for closed loop of synchronizer unit adjustment of allowed phase angle for synchronization adjustment of delay time to close generator breaker adjustment of forward power switch point adjustment of reverse power switch point adjustment of output to external kilowatt meter adjustment of internal fuel limitation...

  • Page 28: Mean And Position Of Led's

    8 Commissioning 8.2 Mean and Position of LED’s Figure 14: Position of LED’s THESEUS Analogue AT 01...
  • Page 29 8 Commissioning Function when LED is on reverse power on phase L1 reverse power on phase L2 reverse power on phase L3 voltage on generator generator frequency = bus frequency voltage on bus phases angles on both sides of generator breaker are equal phase rotations on both sides of generator breaker are equal load is ramping up or down ramp reached at minimum load...

  • Page 30: Initial Setting Up Procedure

    8 Commissioning 8.3 Initial Setting Up Procedure 8.3.1 Wire the inputs of the generator voltages and the current transformers. Next, connect the BUS either or mains volt input connections (refer to fig. 2 page 12). Care must be taken to connect the correct phase rotation for both, current and voltage inputs.

  • Page 31: Adjustment Of Synchronizer Device

    8 Commissioning 8.5 Adjustment of Synchronizer Device 8.5.1 Set the potentiometer P3 for phase angle in middle position. The smaller the phase angle the longer the synchronization time. 8.5.2 Set the potentiometer P4 for required delay time of synchronizer relay. Gas engines must have short delay times, with diesel engines are delay times up to 5 seconds possible.

  • Page 32: Adjustment Of Load Sharing Device In Island Parallel Operation

    8 Commissioning 8.5.9 When satisfied with synchronization, you can start the initial adjustment of the load sharing device. Make sure that immediately after synchronization there is only a minor take-up of load (refer to following chapters) before removing the link between terminals 37 and 38 so that the breaker can close. After closing the breaker, the synchronizer device will be automatically disconnected.

  • Page 33: Adjustment Of Load Share Device In Base Load Mains Operation

    8 Commissioning 8.6.10 Decrease the load to 0 %. If there is different load sharing, speed differences exist in governor speed adjustment. With readjustment of the external speed setting potentiometer of the governor of one genset you can correct this failure. 8.6.11 Proceed with installation 1 to 3, 1 to 4 etc.
  • Page 34 8 Commissioning 8.7.3 To synchronize, remove the link between the terminals 33 and 34. 8.7.4 After synchronization set the genset to partial load 20 % with the external speed setting potentiometer. 8.7.5 Connect a voltmeter with 10 V DC measuring range to terminals 15 and 16. A positive measured voltage is proportional to the generator output power and can be adjusted with the potentiometer P9.

  • Page 35: Adjustment Of Load Sharing Device With Controlled Mains Supply

    8 Commissioning 8.7.16 Proceed with installation 1 to 3, 1 to 4 etc. in the same way, thereby readjustments of the potentiometer P9 and the speed setting may only be made on the new added genset. 8.7.17 Now you can drive further gensets parallel together. If the adjustment described before was correct, now you have here a good load sharing also.

  • Page 36: Adjustment Of Forward Power And Reverse Power Relays

    8 Commissioning 8.9.3 If you want an internal load limitation, slowly turn the potentiometer P8 counterclockwise until you reach the demanded maximum load. 8.9.4 If you want an external load limitation, turn at first the internal potentiometer P8 clockwise to maximum. Then slowly turn the external connected load limitation potentiometer as shown in fig.

  • Page 37: Adjustment Of Load Ramp Device

    8 Commissioning 8.11.2 With the speed drop by putting on load you can adjust the droop by turning the droop potentiometer. The droop has to be adjusted the same for all gensets and should be about 4 %. 8.12 Adjustment of Load Ramp Device In island single operation the load ramp is not allowed, because the output power allways depends on the unknown load level.
  • Page 38 8 Commissioning reasons of hardware design, however, this setting can only be achieved when the terminals 29 and 30 are open. Set by opening the link between the terminals 31 and 32 to zero load. Turn the potentiometer P12 (base) 10 times counterclockwise and then 2 times clockwise. Link the terminals 29 and 30 to ramp up to the set value.

  • Page 39: Ordering Specification

    9 Ordering Specification 9 Ordering Specification Please order: THESEUS Analog AT 01 THESEUS Analogue AT 01...

  • Page 40: Figure List

    10 Figure List 10 Figure List Figure 1: Block Diagram of Analogue THESEUS AT 01 ............6 Figure 2: Connection of Bus Voltages and Current Transformers .......... 13 Figure 3: Connection with Control Unit of Series E 1 - F and E 2 - F ........14 Figure 4: Connection with Control Unit of Series E 6 up to E 40 ...........

  • Page 41: Order Specifications For Manuals

    There is no charge for our technical manuals ordered in reasonable quantities. Order the necessary manuals on our speed governors from your nearest HEINZMANN location. (Please click on “HEINZMANN location” to see the list of our subsidiaries and agents in the world). Please include the following information: • your name, •...
  • Page 42 Title Please send me your new sales documentation about ( ) the HEINZMANN Analogue Governors Application:............ ( ) the HEINZMANN Digital Governors Application:............ ( ) the HEINZMANN Gas Engine Equipment Application:............ Company ............................Contact Person..........................Department ........................... Adress............Country/Code/Town..........Phone............Fax .................

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