Deif PPU 300 Commissioning Manual
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Deif PPU 300 Commissioning Manual

Deif PPU 300 Commissioning Manual

Paralleling and protection unit
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COMMISSIONING GUIDELINES
Paralleling and Protection Unit
PPU 300
DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · info@deif.com · www.deif.com
Document no.: 4189341106B

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  • Page 1 PPU 300 DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · info@deif.com · www.deif.com isenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · info@deif.com · www.deif.com 14 9614 ·...

  • Page 2: Table Of Contents

    1.1.3 Switchboard panel examples ........................................ 1.1.4 Software versions ............................................1.1.5 Technical support ............................................1.1.6 List of technical documentation for PPU 300 ................................1.2 Warnings and safety ..............................................1.2.1 Safety during installation and operation ..................................1.2.2 Design, drawings and FAT test ......................................
  • Page 3 PPU 300 Commissioning guidelines 4189341106 UK 3.3.2 Non-plug and play connections in the network ..............................3.3.3 Configuring a switch (optional) ......................................3.3.4 Checking the Ethernet connections ....................................3.4 Checking each display unit ..........................................3.4.1 Display unit ..............................................3.5 Firmware update ...............................................
  • Page 4 PPU 300 Commissioning guidelines 4189341106 UK 6.2 Relay-controlled regulators ..........................................6.2.1 Checking the control range ......................................... 6.2.2 Setting up relay-controlled regulators ..................................6.2.3 Tuning P regulators ........................................... 6.3 Analogue-controlled regulators ........................................6.3.1 Setting up analogue-controlled regulators ................................6.3.2 External resistor for GOV/AVR ......................................
  • Page 5 PPU 300 Commissioning guidelines 4189341106 UK 9.1.2 Troubleshooting analogue-controlled governors (mA signal) ........................9.2 Alarms ....................................................9.2.1 Troubleshooting alarms .......................................... 9.3 Terminals ..................................................9.3.1 Troubleshooting terminal damage ....................................9.3.2 Troubleshooting the MPU input ......................................10. Glossary 10.1 Terms and abbreviations ...........................................

  • Page 6: Introduction

    1.1.3 Switchboard panel examples The PPU 300 can be used for a wide range of applications. As the example below shows, in addition to the controller display unit, a complex application like a tanker's switchboard panel typically includes extra voltage, current, frequency and synchronisation indicators, as well as manual operation buttons and switches.
  • Page 7 PPU 300 Commissioning guidelines 4189341106 UK Figure 1.1 Switchboard example for a controller in a complex application 1200 -100 Configure Tools Info Log on Alarm Live data Figure 1.2 Switchboard example for controller in a simple application Configure Tools Info...

  • Page 8: Software Versions

    PC software 1.0.3.x 1.1.5 Technical support You can read about service and support options on the DEIF website, www.deif.com. You can also find contact details on the DEIF website. You have the following options if you need technical support: • Help: The display unit includes context-sensitive help.

  • Page 9: Warnings And Safety

    PPU 300 Commissioning guidelines 4189341106 UK Document Contents • Principles • General controller sequences, functions and protections • GENSET controller • Protections and alarms • AC configuration and nominal settings • Breaker and synchronisation Designer's handbook • Regulation • Load sharing •...

  • Page 10: Design, Drawings And Fat Test

    PPU 300 Commissioning guidelines 4189341106 UK DANGER! Hazardous live currents and voltages. Do not touch any terminals, especially the AC measurement inputs and the relay terminals. Touching the terminals could lead to injury or death. 1.2.2 Design, drawings and FAT test These commissioning guidelines assume that all of these tasks are completed before the commissioning: 1.

  • Page 11: Controller Power Supply

    PPU 300 Commissioning guidelines 4189341106 UK 1.2.4 Controller power supply If the controller has no power supply, it is OFF and does not provide any protection. The controller cannot enforce any trips, shutdowns or latches when it is off. The controller does not provide any control or load sharing. All the controller relays de- energise.

  • Page 12: Legal Information

    1.3 Legal information 1.3.1 Third party equipment DEIF takes no responsibility for the installation or operation of any third party equipment, including the genset. Contact the genset company if you have any doubt about how to install or operate the genset.

  • Page 13: Disclaimer

    DEIF A/S reserves the right to change any of the contents of this document without prior notice. The English version of this document always contains the most recent and up-to-date information about the product. DEIF does not take responsibility for the accuracy of translations, and translations might not be updated at the same time as the English document.

  • Page 14: Preparation For Commissioning

    Please refer to Apple's support page for Bonjour, regarding information and downloading. http://www.apple.com/support/bonjour/ See the PICUS manual for the system requirements to run PICUS. DEIF supporters and other commissioning technicians have found these tools useful during controller commissioning: Tool Used to Multimeter, with accessories and...

  • Page 15: Software

    You must install Bonjour, if you do not already have this installed on your computer. This service is used for the network detection on the DEIF network. PICUS uses Bonjour to detect all controllers that are connected to the same network.

  • Page 16: Io Setup And Parameter Configuration

    PPU 300 Commissioning guidelines 4189341106 UK Drawing Used to Single-line diagram Set up or check the single-line diagram in PICUS Detailed drawings Configure the inputs and outputs in PICUS 2.3.2 IO setup and parameter configuration The following information must be available:...

  • Page 17: Avr Information

    PPU 300 Commissioning guidelines 4189341106 UK 2.3.7 AVR information To avoid delays during commissioning, ensure that the manufacturer's information is available for each AVR that the controllers will regulate. This information should include: • Instructions on setting the AVR initial voltage.

  • Page 18: Controller Checks

    Therefore, the breakers and engine start MUST also be disabled. Activating and deactivating switchboard control DEIF recommends that you put the controller under switchboard control at several points during commissioning. These are called Activate switchboard control and Deactivate switchboard control respectively.

  • Page 19: Ethernet Communication

    PPU 300 Commissioning guidelines 4189341106 UK Expected Location Unexpected state and action state Wait for the self-check and/or software update to complete. If necessary, use the hardware module self-check LEDs to find and replace the defective hardware PSM3.1 Power Green On the front plate of PSM3.1...

  • Page 20: Non-Plug And Play Connections In The Network

    • Controllers that are connected using a switch to a SCADA server or AMS. A technician with network expertise must configure the switch. • Controllers with a redundant connection to a SCADA server or AMS. See Hardware characteristics and configuration, DEIF Ethernet network in the Designer's handbook for further information. 3.3.3 Configuring a switch (optional) A switch can be used with the Ethernet connections to connect a third party system, for example, SCADA or AMS.
  • Page 21 The controllers do not include a firewall or other Internet security measures. It is the customer's responsibility to protect the network. DEIF recommends only connecting the controllers to local networks. The controller uses either IPv6 (Automatic) or IPv4 (Static) addressing for the communication.
  • Page 22 PPU 300 Commissioning guidelines 4189341106 UK 3. Information for the highlighted controller is shown at the right, including IPv6, IP mode, and IPv4 address (if configured). • Using the display unit: ◦ For IPv6: 1. Select Info, from the Home menu.

  • Page 23: Checking The Ethernet Connections

    See Tools, Communication, Configure communication in the Operator's manual for more information about configuring IP addressing. Connecting the switch Connect the switch to the DEIF network by connecting it to an Ethernet communication port on PCM3.1. The switch can also be connected to another PCM3.1 for redundancy. Configuring the switch CAUTION A technician with network expertise must configure the switch.
  • Page 24 PPU 300 Commissioning guidelines 4189341106 UK Pair the display unit to the controller Figure 3.3 Example initial Pair screen • ID: The controller ID. • Label: The controller label. • Host name: The host name from the controller. • Hops: The number of hops used to reach the controller.

  • Page 25: Firmware Update

    Firmware updates are available as .packet files on the DEIF website. 1. Visit: http://www.deif.com/software. 2. Scroll to Software download and choose Multi-line 300, PPU 300 ver. 1.x.x software. 3. Submit your email address to receive a download link to the software.

  • Page 26: Installing Controller Firmware

    PPU 300 Commissioning guidelines 4189341106 UK *Note: Where version is the latest available version number. Both .packet files can now be installed by using the Firmware option in PICUS. 3.5.3 Installing controller firmware INFO Read the software version log for details of all the changes.

  • Page 27: Installing Display Unit Firmware

    PPU 300 Commissioning guidelines 4189341106 UK Failed firmware update See Troubleshooting, Firmware in the PICUS manual for help. 3.5.4 Installing display unit firmware Before updating: Press OK if there is an alarm alert (red pop-up box) on the display unit.

  • Page 28: Checking The Protection Parameters

    PPU 300 Commissioning guidelines 4189341106 UK To check the Emergency stop: 1. Press the switchboard Emergency stop button. 2. Check whether the Emergency stop alarm is shown on the display unit. • If the Emergency stop alarm is shown, then the Emergency stop button is working.

  • Page 29: Checking The Parameters

    Over-frequency, Under-frequency 3.6.3 Checking the parameters The designer should have set all the necessary parameter in each controller during the design phase. However, DEIF recommends that you check that these are suited to the actual site conditions. To check the parameters for each controller: 1.

  • Page 30: System Checks

    4.1.1 Using the controllers to check the system In DEIF's experience, most controller commissioning problems are due to incorrect wiring and/or incorrect configuration (that is, the setup of inputs, outputs and parameters in the controller). These errors cause commissioning problems and delays while the commissioning engineer tries to find the problem.

  • Page 31: Equipment Checks

    INFO These guidelines are for the commissioning of third party equipment, and are provided to help the overall commissioning. DEIF does not however take any responsibility for third party equipment. DANGER! Ensure that the engine is safe to start before starting the engine.

  • Page 32: Setting The Avr

    DEIF does not however take any responsibility for third party equipment. This section is only relevant if the DEIF controller controls the AVR. The generator must be able to produce a steady voltage before you can use the DEIF controller to control the excitation.

  • Page 33: Testing The Switchboard Gov And Avr Controls

    PPU 300 Commissioning guidelines 4189341106 UK Relay control AVR adjustment Switchboard control must be activated. The genset breaker must be open, and there must be no load on the genset. 1. Start the genset (if it is not already running).

  • Page 34: Testing The Overspeed Protection

    PPU 300 Commissioning guidelines 4189341106 UK 3. Use the Manual AVR increase control on the switchboard (if present). Does the generator voltage increase? • Yes: Continue with the test. • No: Troubleshoot the switchboard's AVR up wiring. Alternatively, the generator could be the problem.

  • Page 35: Breaker

    PPU 300 Commissioning guidelines 4189341106 UK 5.2 Breaker 5.2.1 Checking the phase sequence Controller types: The information here applies to ALL controller types. DANGER! The phase sequence across the breaker MUST be checked and correct before the breaker is closed for the first time.

  • Page 36: Checking The Voltage Across The Breaker When Synchronised

    PPU 300 Commissioning guidelines 4189341106 UK Phase sequence ACM3.1 meter BB-L1 BB-L2 BB-L3 Breaker Controlled equipment 5. Check that the phase sequence is the same at the equipment (1) and across the breaker on the busbar (2). ACM3.1 BB-L1 BB-L2...
  • Page 37 PPU 300 Commissioning guidelines 4189341106 UK DANGER! The voltage across the breaker when synchronised MUST be checked before the breaker is closed for the first time. A voltage difference can be extremely dangerous and could result in personal injury or death, and serious equipment damage.

  • Page 38: Checking Breaker Open And Close Wiring

    PPU 300 Commissioning guidelines 4189341106 UK ACM3.1 BB-L1 BB-L2 BB-L3 Controlled equipment 10. The voltage across the breaker should be 0 V for each phase. If it is not, correct the wiring. 11. Under Configure > Parameters > Breakers > [Breaker] > Synchronisation setting > Sync. type, change the synchronisation setting to Dynamic.

  • Page 39: Checking De-Loading

    PPU 300 Commissioning guidelines 4189341106 UK DANGER! You must complete all the previous commissioning steps before closing the breaker to the live busbar. You must be sure that the phase sequences on either side of the breaker match. You must be sure that the voltage across the breaker is 0 V for each phase when synchronised.

  • Page 40: Checking The System Stability By Running Under Switchboard Control

    PPU 300 Commissioning guidelines 4189341106 UK Table 5.1 Droop definitions Droop name Description Governor or AVR droop The droop setting of the governor or AVR. This droop value is related to the engine speed. Since engine speed and the generator frequency Speed droop are proportional, you can also use the generator frequency to calculate speed droop.

  • Page 41: Measuring Speed Droop

    5.4.4 Measuring speed droop DEIF recommends that the speed droop for each genset in the system is 4 %. A lower speed droop gives a faster dynamic control loop. However, if the dynamic control loop is too fast, the system is unstable.

  • Page 42: Adjusting Speed Droop

    Program the droop that is needed in the electronic governor. Refer to the governor supplier for information on how to do this. 5.4.6 Measuring voltage droop DEIF recommends that the voltage droop for each genset in the system is 4 %. The voltage droop for the shaft generator must also be 4 %.
  • Page 43 PPU 300 Commissioning guidelines 4189341106 UK • If the load power factor is 1, the reactive load (Q) is 0 kvar. 2. Activate switchboard control. 3. Start the generator, with no reactive load connected. Check that the generator reactive power (kvar) is zero. Record the generator reactive power and voltage.

  • Page 44: Adjusting Voltage Droop

    PPU 300 Commissioning guidelines 4189341106 UK Figure 5.2 Voltage droop graph for the example Voltage 220.0 219.0 218.0 217.0 216.0 215.0 214.0 213.0 212.0 211.0 210.0 1000 Reactive power [kvar] Droop = (220.0 - 211.3) / (985 - 0) × 1000 / 220 × 100 = 4.0 % 5.4.7 Adjusting voltage droop...

  • Page 45: Tune Regulators

    The control output for the governor is either relay outputs, or an analogue output (including PWM outputs)). The control output for the AVR is either relay outputs, or an analogue output, or the AVR is not controlled by the DEIF controller. You can then follow the steps in the relevant section to tune the regulators.

  • Page 46: Optimum Regulation

    PPU 300 Commissioning guidelines 4189341106 UK The DEIF controller is the secondary regulator. It does not regulate the engine's fuel directly. Rather, it modifies the set point for the governor, for example, based on the power management requirements. The DEIF controller can use proportional or PID control.

  • Page 47: Relay-Controlled Regulators

    PPU 300 Commissioning guidelines 4189341106 UK The example below shows regulation that is too slow, and cannot return the operating value to the set point. Figure 6.3 Example of regulation that is too slow to respond to a load increase...

  • Page 48: Setting Up Relay-Controlled Regulators

    PPU 300 Commissioning guidelines 4189341106 UK Checking the control range example If the nominal frequency is 50 Hz, the frequency control range for the governor is typically 48 to 52 Hz. If one pulse from the relay outputs corresponds to a 1 Hz change, it will be impossible to control the frequency accurately enough for synchronisation.
  • Page 49 PPU 300 Commissioning guidelines 4189341106 UK Governor tuning parameters For relay-controlled governors, set these parameters under Configure > Parameters > Regulators > Governor: Relay output settings: Heading Parameters Frequency regulation Kp, Deadband Frequency synchronisation Phase synchronisation Power regulation Kp, Deadband...

  • Page 50: Analogue-Controlled Regulators

    PPU 300 Commissioning guidelines 4189341106 UK 6.3 Analogue-controlled regulators 6.3.1 Setting up analogue-controlled regulators You can configure an analogue input for the controller, so that a corresponding offset is added to the regulator output at startup. See Regulation, Governor analogue regulation function and Regulation, AVR analogue regulation function in the Designer's handbook for more information about the analogue offset.

  • Page 51: Tuning Pid Regulators

    PPU 300 Commissioning guidelines 4189341106 UK 6.3.4 Tuning PID regulators The analogue-controlled regulators use PID control. The PID settings must be checked as part of the commissioning. Governor tuning parameters For analogue-controlled governors, set these parameters under Configure > Parameters > Regulators > Governor:...
  • Page 52 PPU 300 Commissioning guidelines 4189341106 UK Check the control response of the system. a. If the response is unstable, then repeat steps 5 to 7 until the response is stable. b. If the response is stable, then go to step 8.

  • Page 53: Tuning Governor Regulators

    PPU 300 Commissioning guidelines 4189341106 UK In general, for tuning the controllers, a slow response is better than a fast, unstable response. The default PID settings for analogue-controlled regulators are sensitive, and normally need adjustment: 1. You must have already adjusted the analogue control parameters.

  • Page 54: Tuning For Phase Synchronisation

    PPU 300 Commissioning guidelines 4189341106 UK Create changes during tuning as follows: 1. Activate switchboard control. 2. Use the switchboard GOV up or GOV down controls to ensure that the frequency is 1 Hz more or less than the busbar frequency.

  • Page 55: Tuning Avr Regulators

    0 %, the controller ignores the power load sharing set point, to achieve the frequency set point. DEIF recommends that you start with the default value, and then, if necessary, adjust this parameter. If P weight is too low, the load sharing will not be effective and the load will float between the controllers. If P weight is too high, the frequency regulation will be too slow, for example, when a new large load connects.

  • Page 56: Tuning For Reactive Power Load Sharing

    PPU 300 Commissioning guidelines 4189341106 UK 4. Alternatively, with switchboard control deactivated, increase or decrease the load, and observe the response of the reactive power to the regulator. Use the observation to tune the regulator. 6.5.3 Tuning for reactive power load sharing To tune the reactive power load sharing, the genset and at least one other genset must be connected to the busbar.

  • Page 57: System Testing

    PPU 300 Commissioning guidelines 4189341106 UK 7. System testing 7.1 GENSET controller 7.1.1 Basic GENSET controller tests After completing the previous commissioning steps, the GENSET controller should have the correct protections and parameters. The engine start and stop, and the breaker close and open should function correctly, and the regulators should be tuned correctly.

  • Page 58: Genset Controller Functions

    PPU 300 Commissioning guidelines 4189341106 UK b. When the breaker closes, press Open breaker to open the genset breaker. Does the breaker de-load? Does the breaker open? c. Activate switchboard control. Using the switchboard Manual GOV increase control, increase the frequency to 1 Hz above the nominal value.

  • Page 59: Shaft Generator Controller

    PPU 300 Commissioning guidelines 4189341106 UK Functions • PID regulators for analogue outputs • P regulators for relay outputs ◦ Relay period time and Minimum ON time configurable • Set point selection ◦ Select mode or external set point, using DI, CustomLogic, or Modbus •...

  • Page 60: Shaft Generator Controller Functions

    PPU 300 Commissioning guidelines 4189341106 UK Basic SHAFT generator controller tests DANGER! Complete all the previous commissioning steps before performing the basic SHAFT generator controller tests. For the SHAFT generator controller: 1. Deactivate switchboard control. Press LOCAL so that the controller is in LOCAL mode.

  • Page 61: Shore Connection Controller Functions

    PPU 300 Commissioning guidelines 4189341106 UK For the SHORE connection controller: 1. Deactivate switchboard control. Press LOCAL so that the controller is in LOCAL mode. 2. Press Close breaker . Do the GENSET controllers with external set point (network) activated synchronise the busbar to the shore connection? Is the synchronisation fast enough? 3.

  • Page 62: Bus Tie Breaker Controller Functions

    The testing of CustomLogic depends on the specific functions and/or sequences created by the customer. DEIF cannot therefore give any specific guidelines on testing the controller's CustomLogic.

  • Page 63: Plc

    The controllers are designed to work with a PLC. As part of the commissioning, the PLC and its interactions with the controllers should be thoroughly tested. The testing of the PLC depends on the system and the specific functions and/or sequences created by the customer. DEIF cannot therefore give any specific guidelines on testing the PLC.

  • Page 64: Final Commissioning Actions

    PPU 300 Commissioning guidelines 4189341106 UK 8. Final commissioning actions 8.1 Update the documentation 8.1.1 Backing up the controller information You can back up or restore selected features from or to the controller. You can also create a complete local copy (Offline project) of the controller settings.

  • Page 65: Finalising The Operator's Manual

    PPU 300 Commissioning guidelines 4189341106 UK 3. Select Tools > Report 4. Make sure all features are selected. 5. Select Print in the right side panel. • PICUS creates a report from the features selected. 6. Use Print to print the report from your computer and Close to return to PICUS.
  • Page 66 PPU 300 Commissioning guidelines 4189341106 UK Applies to Description Notes Each controller The phase sequence is checked. Each controller The breaker open and close is checked. Under switchboard control, synchronisation and de-loading are Each controller checked. GENSET controller The speed droop is checked, and adjusted if necessary.

  • Page 67: Troubleshooting

    PPU 300 Commissioning guidelines 4189341106 UK 9. Troubleshooting 9.1 Regulators 9.1.1 Troubleshooting relay-controlled governors Problem The relay-controlled governor does not respond when the controller tries to raise or lower the frequency. Solutions Ensure that the wiring from the controller to the governor is correct.

  • Page 68: Troubleshooting Analogue-Controlled Governors (Ma Signal)

    PPU 300 Commissioning guidelines 4189341106 UK 9.1.2 Troubleshooting analogue-controlled governors (mA signal) Problem The analogue-controlled governor does not respond when the controller tries to raise or lower the frequency by changing the analogue output mA signal. Solutions Ensure that the wiring from the controller to the governor is correct.

  • Page 69: Alarms

    PPU 300 Commissioning guidelines 4189341106 UK INFO This method can be adapted to troubleshoot any controller analogue output with a mA signal. 9.2 Alarms 9.2.1 Troubleshooting alarms INFO During commissioning, there is often a wider range of possible causes for alarms. This makes it difficult to provide comprehensive alarm troubleshooting information.

  • Page 70: Glossary

    The 3-phase apparent power, measured in kVA. Regulates the genset voltage. The AVR is third-party equipment. The AVR can Automatic voltage have a fixed voltage set point. Alternatively, the DEIF controller can control the regulator AVR. The generator supplies a constant load. For GENSET controllers, configure the Base load asymmetric load sharing parameters to have a base load from a specific genset.
  • Page 71 A generator is connected to the system if it is running, synchronised with the Connected busbar, and its breaker is closed. DEIF equipment that measures system conditions and then uses outputs to make Controller the system respond appropriately. Current transformer...
  • Page 72 Power The 3-phase active power, measured in kW. Power factor The 3-phase power factor. Power in Control The DEIF utility software, used to design, configure, troubleshoot and monitor a PICUS Utility Software system. Power supply module A replaceable PCB that powers the controller. This module includes three relay PSM3.1...

  • Page 73: Units

    The gensets, the other power sources, all breakers, the busbars, and all their System controllers. Within the system, the DEIF controllers work together to supply the power required safely and efficiently. Equipment other than the DEIF controller. For example: The genset, the genset Third-party equipment engine control system, the wiring, the busbars, and the switchboard.
  • Page 74 PPU 300 Commissioning guidelines 4189341106 UK Table 10.1 Units used in the documentation Unit Name Measures US unit US name Conversion Alternative units ampere Current 1 bar = 0.980665 atmosphere (atm) pounds per Pressure 1 bar = 14.5 psi square inch...

  • Page 75: Symbols

    PPU 300 Commissioning guidelines 4189341106 UK 10.3 Symbols 10.3.1 Symbols for notes Safety notes DANGER! This highlights dangerous situations. If the guidelines are not followed, these situations could result in death, serious personal injury, and equipment damage or destruction. CAUTION This highlights potentially dangerous situations.

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