Deif PPU 300 Kurzanleitung

DEIF A/S · Frisenborgvej 33 · DK-7800 Skive · Tel.: +45 9614 9614 · Fax: +45 9614 9615 · info@deif.com · www.deif.com

COMMISSIONING GUIDELINES

Paralleling and Protection Unit

PPU 300

Document no.: 4189341106B

1. Introduction

1.1 About the Commissioning guidelines......................................................................................................................................................................................6

1.1.1 General purpose.............................................................................................................................................................................................................................6

1.1.2 Intended users of the Commissioning guidelines.................................................................................................................................................. 6

1.1.3 Switchboard panel examples................................................................................................................................................................................................6

1.1.4 Software versions.......................................................................................................................................................................................................................... 8

1.1.5 Technical support...........................................................................................................................................................................................................................8

1.1.6 List of technical documentation for PPU 300............................................................................................................................................................8

1.2 Warnings and safety................................................................................................................................................................................................................................ 9

1.2.1 Safety during installation and operation ...................................................................................................................................................................... 9

1.2.2 Design, drawings and FAT test.........................................................................................................................................................................................10

1.2.3 Hot commissioning and retrofits...................................................................................................................................................................................... 10

1.2.4 Controller power supply..........................................................................................................................................................................................................11

1.2.5 Connect the controller protective earth.......................................................................................................................................................................11

1.2.6 Switchboard control...................................................................................................................................................................................................................11

1.2.7 Factory settings ...........................................................................................................................................................................................................................11

1.2.8 Remote-controlled starts........................................................................................................................................................................................................11

1.2.9 Electrostatic discharge ...........................................................................................................................................................................................................11

1.2.10 Do not manually override active alarm actions..................................................................................................................................................... 11

1.3 Legal information.....................................................................................................................................................................................................................................12

1.3.1 Third party equipment............................................................................................................................................................................................................. 12

1.3.2 Warranty............................................................................................................................................................................................................................................ 12

1.3.3 Open source software............................................................................................................................................................................................................. 12

1.3.4 Trademarks..................................................................................................................................................................................................................................... 12

1.3.5 Copyright...........................................................................................................................................................................................................................................12

1.3.6 Disclaimer ....................................................................................................................................................................................................................................... 13

2. Preparation for commissioning

2.1 Tools.................................................................................................................................................................................................................................................................... 14

2.1.1 Tools required................................................................................................................................................................................................................................ 14

2.2 Software........................................................................................................................................................................................................................................................... 15

2.2.1 Downloading and installing PICUS................................................................................................................................................................................15

2.3 Information.................................................................................................................................................................................................................................................... 15

2.3.1 System drawings.........................................................................................................................................................................................................................15

2.3.2 IO setup and parameter configuration.........................................................................................................................................................................16

2.3.3 AC protections...............................................................................................................................................................................................................................16

2.3.4 Transformer information.........................................................................................................................................................................................................16

2.3.5 Breaker information...................................................................................................................................................................................................................16

2.3.6 Governor information............................................................................................................................................................................................................... 16

2.3.7 AVR information........................................................................................................................................................................................................................... 17

3. Controller checks

3.1 BEFORE connecting the controller power supply.....................................................................................................................................................18

3.1.1 Disable the breakers ...............................................................................................................................................................................................................18

3.1.2 Disable the engine start......................................................................................................................................................................................................... 18

3.1.3 Activate switchboard control...............................................................................................................................................................................................18

3.2 Checking each controller..................................................................................................................................................................................................................18

3.2.1 Connecting the controller power supply.....................................................................................................................................................................18

3.2.2 Checking the controller LEDs............................................................................................................................................................................................ 18

3.3 Ethernet communication...................................................................................................................................................................................................................19

3.3.1 Plug and play connections in the network................................................................................................................................................................19

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3.3.2 Non-plug and play connections in the network.....................................................................................................................................................20

3.3.3 Configuring a switch (optional)......................................................................................................................................................................................... 20

3.3.4 Checking the Ethernet connections.............................................................................................................................................................................. 23

3.4 Checking each display unit............................................................................................................................................................................................................ 23

3.4.1 Display unit...................................................................................................................................................................................................................................... 23

3.5 Firmware update.......................................................................................................................................................................................................................................25

3.5.1 Connecting to a controller with PICUS....................................................................................................................................................................... 25

3.5.2 Downloading firmware.............................................................................................................................................................................................................25

3.5.3 Installing controller firmware ............................................................................................................................................................................................. 26

3.5.4 Installing display unit firmware..........................................................................................................................................................................................27

3.6 Safety..................................................................................................................................................................................................................................................................27

3.6.1 Checking the Emergency stop..........................................................................................................................................................................................27

3.6.2 Checking the protection parameters............................................................................................................................................................................ 28

3.6.3 Checking the parameters......................................................................................................................................................................................................29

4. System checks

4.1 Working through the alarms.......................................................................................................................................................................................................... 30

4.1.1 Using the controllers to check the system................................................................................................................................................................30

4.1.2 Testing the controller AC alarms..................................................................................................................................................................................... 30

5. Equipment checks

5.1 Genset................................................................................................................................................................................................................................................................31

5.1.1 Important information...............................................................................................................................................................................................................31

5.1.2 Starting the engine for the first time..............................................................................................................................................................................31

5.1.3 Setting the governor................................................................................................................................................................................................................. 31

5.1.4 Setting the AVR............................................................................................................................................................................................................................ 32

5.1.5 Testing the switchboard GOV and AVR controls.................................................................................................................................................33

5.1.6 Testing the overspeed protection....................................................................................................................................................................................34

5.2 Breaker..............................................................................................................................................................................................................................................................35

5.2.1 Checking the phase sequence......................................................................................................................................................................................... 35

5.2.2 Checking the voltage across the breaker when synchronised..................................................................................................................36

5.2.3 Checking breaker open and close wiring..................................................................................................................................................................38

5.3 Synchronisation and de-loading................................................................................................................................................................................................38

5.3.1 Checking synchronisation.................................................................................................................................................................................................... 38

5.3.2 Checking de-loading.................................................................................................................................................................................................................39

5.4 Droop.................................................................................................................................................................................................................................................................. 39

5.4.1 Controller types............................................................................................................................................................................................................................ 39

5.4.2 Introduction to droop................................................................................................................................................................................................................ 39

5.4.3 Checking the system stability by running under switchboard control.................................................................................................. 40

5.4.4 Measuring speed droop......................................................................................................................................................................................................... 41

5.4.5 Adjusting speed droop............................................................................................................................................................................................................ 42

5.4.6 Measuring voltage droop.......................................................................................................................................................................................................42

5.4.7 Adjusting voltage droop..........................................................................................................................................................................................................44

6. Tune regulators

6.1 Introduction...................................................................................................................................................................................................................................................45

6.1.1 Controller types............................................................................................................................................................................................................................ 45

6.1.2 Introduction to regulation.......................................................................................................................................................................................................45

6.1.3 Optimum regulation...................................................................................................................................................................................................................46

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6.2 Relay-controlled regulators............................................................................................................................................................................................................47

6.2.1 Checking the control range................................................................................................................................................................................................. 47

6.2.2 Setting up relay-controlled regulators..........................................................................................................................................................................48

6.2.3 Tuning P regulators................................................................................................................................................................................................................... 48

6.3 Analogue-controlled regulators..................................................................................................................................................................................................50

6.3.1 Setting up analogue-controlled regulators............................................................................................................................................................... 50

6.3.2 External resistor for GOV/AVR......................................................................................................................................................................................... 50

6.3.3 Checking the control range................................................................................................................................................................................................. 50

6.3.4 Tuning PID regulators..............................................................................................................................................................................................................51

6.4 Tuning governor regulators............................................................................................................................................................................................................53

6.4.1 Tuning for frequency regulation....................................................................................................................................................................................... 53

6.4.2 Tuning for frequency synchronisation..........................................................................................................................................................................53

6.4.3 Tuning for phase synchronisation...................................................................................................................................................................................54

6.4.4 Tuning for power regulation................................................................................................................................................................................................ 54

6.4.5 Tuning for power load sharing...........................................................................................................................................................................................54

6.5 Tuning AVR regulators........................................................................................................................................................................................................................ 55

6.5.1 Tuning for voltage regulation..............................................................................................................................................................................................55

6.5.2 Tuning for reactive power regulation............................................................................................................................................................................ 55

6.5.3 Tuning for reactive power load sharing...................................................................................................................................................................... 56

7. System testing

7.1 GENSET controller................................................................................................................................................................................................................................. 57

7.1.1 Basic GENSET controller tests........................................................................................................................................................................................ 57

7.1.2 GENSET controller functions.............................................................................................................................................................................................58

7.2 SHAFT generator controller........................................................................................................................................................................................................... 59

7.2.1 Basic SHAFT generator controller tests.................................................................................................................................................................... 59

7.2.2 SHAFT generator controller functions.........................................................................................................................................................................60

7.3 SHORE connection controller...................................................................................................................................................................................................... 60

7.3.1 Basic SHORE connection controller tests................................................................................................................................................................60

7.3.2 SHORE connection controller functions.................................................................................................................................................................... 61

7.4 BUS TIE breaker controller............................................................................................................................................................................................................. 61

7.4.1 Basic BUS TIE breaker controller tests......................................................................................................................................................................61

7.4.2 BUS TIE breaker controller functions.......................................................................................................................................................................... 62

7.5 Customised functions and sequences.................................................................................................................................................................................62

7.5.1 Testing CustomLogic................................................................................................................................................................................................................62

7.6 PLC....................................................................................................................................................................................................................................................................... 63

7.6.1 Testing the PLC............................................................................................................................................................................................................................63

7.7 Failure scenarios......................................................................................................................................................................................................................................63

7.7.1 Testing blackout close............................................................................................................................................................................................................. 63

8. Final commissioning actions

8.1 Update the documentation..............................................................................................................................................................................................................64

8.1.1 Backing up the controller information.......................................................................................................................................................................... 64

8.1.2 Finalising the operator's manual......................................................................................................................................................................................65

8.1.3 Finalising the commissioning report............................................................................................................................................................................. 65

8.1.4 Commissioning checklist.......................................................................................................................................................................................................65

9. Troubleshooting

9.1 Regulators......................................................................................................................................................................................................................................................67

9.1.1 Troubleshooting relay-controlled governors............................................................................................................................................................67

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9.1.2 Troubleshooting analogue-controlled governors (mA signal).................................................................................................................... 68

9.2 Alarms................................................................................................................................................................................................................................................................69

9.2.1 Troubleshooting alarms..........................................................................................................................................................................................................69

9.3 Terminals.........................................................................................................................................................................................................................................................69

9.3.1 Troubleshooting terminal damage..................................................................................................................................................................................69

9.3.2 Troubleshooting the MPU input........................................................................................................................................................................................69

10. Glossary

10.1 Terms and abbreviations...................................................................................................................................................................................................................70

10.1.1 Terms and abbreviations....................................................................................................................................................................................................... 70

10.2 Units.....................................................................................................................................................................................................................................................................73

10.2.1 Units......................................................................................................................................................................................................................................................73

10.3 Symbols............................................................................................................................................................................................................................................................75

10.3.1 Symbols for notes.......................................................................................................................................................................................................................75

10.3.2 Mathematical symbols.............................................................................................................................................................................................................75

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1. Introduction

1.1 About the Commissioning guidelines

1.1.1 General purpose

The commissioning guidelines provide information for a thorough, safe and effective commissioning of controller(s), within the

system.

DANGER!

Commissioning is the most risky period of operation. Commissioning errors can lead to personal injury or

death, or equipment damage. These guidelines cannot anticipate or include every possible commissioning

problem. Commissioning must therefore be done thoughtfully, systematically and carefully by qualified and

experienced personnel.

DANGER!

DEIF does not accept any responsibility for wiring errors.

DANGER!

The controllers interface to third party equipment. DEIF does not accept any responsibility for the operation

of third party equipment.

INFO

The commissioning guidelines provide information about checking third-party equipment, for example, the

switchboard wiring. This information is provided to help ensure a successful commissioning of the entire system.

However, DEIF does not accept any responsibility for the operation of third party equipment.

1.1.2 Intended users of the Commissioning guidelines

The commissioning guidelines are primarily for the person who commissions the controller.

DANGER!

To prevent personal injury and/or damage to equipment, you must read these Commissioning guidelines

before connecting the controller to a power supply.

The commissioning guidelines can be useful to the designers working with the controller during the design process.

Operators may find the commissioning guidelines useful for troubleshooting.

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. These indicators and switches are useful

during commissioning.

However, for example, a yacht switchboard panel might consist of only a controller display unit. The commissioning must be

adapted accordingly. There is no substitute for carefully thinking through each commissioning step, based on the actual

system.

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Figure 1.1 Switchboard example for a controller in a complex application

Log on LogAlarm Live data

Configure Tools Info

200

400 600 1200 kW

-100

200

600

400

200

400 600 Hz

Figure 1.2 Switchboard example for controller in a simple application

Log on LogAlarm Live data

Configure Tools Info

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1.1.4 Software versions

The information in this document corresponds to the following software versions.

Table 1.1 Software versions

Software Details Version

PCM APPL Controller application 1.0.0.x

DU APPL Display unit application 1.0.5.x

PICUS 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.

• Technical documentation: Download all the product technical documentation from the DEIF website:

www.deif.com/documentation

• Training: DEIF regularly offers training courses at the DEIF offices worldwide.

• Support: DEIF offers 24-hour support. See www.deif.com for contact details. There may be a DEIF subsidiary located near

you. You can also e-mail [email protected].

• Service: DEIF engineers can help with design, commissioning, operating and optimisation.

1.1.6 List of technical documentation for PPU 300

Document Contents

Data sheet

• System description and functions

• Controller applications, functions, hardware and protections

• Technical specifications

• Hardware modules, display unit, and accessories

• Ordering information

Quick start guide

• Mounting

• Connecting wiring

• PICUS (PC software)

◦ Download and install

◦ Controller configuration

• Display unit overview

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Document Contents

Designer's handbook

• Principles

• General controller sequences, functions and protections

• GENSET controller

• Protections and alarms

• AC configuration and nominal settings

• Breaker and synchronisation

• Regulation

• Load sharing

• Hardware characteristics

• PICUS (including permissions)

• CustomLogic

• Modbus

Installation instructions

• Tools and materials

• Mounting

• Minimum wiring for the controller

• Wiring for hardware module terminals

• Wiring for controller functions

• Wiring communication

• Wiring the display unit

Commissioning guidelines

• Tools, software and information required

• Controller, system and equipment checks

• Regulator tuning

• System testing

• Troubleshooting

Operator's manual

• Controller equipment (push-buttons and LEDs)

• Operating the system

• Alarms and log

• Using the display unit

• Troubleshooting and maintenance

PICUS manual Using PICUS and CustomLogic

Modbus tables

• Modbus address list

◦ PLC addresses

◦ Corresponding controller functions

• Descriptions for function codes, function groups

1.2 Warnings and safety

1.2.1 Safety during installation and operation

Installing and operating the equipment may require work with dangerous currents and voltages. The installation must only be

carried out by authorised personnel who understand the risks involved in working with electrical equipment.

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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. Control system design

• System single-line drawing created and broadcast to the controllers

• Controllers allocated and configured for their unique controller ID

• I/O configuration created and written to each controller

• Parameters created and written to each controller

• Optional: CustomLogic created and written to each controller

2. System and switchboard drawings completed

3. Factory acceptance test (FAT) completed

1.2.3 Hot commissioning and retrofits

These commissioning guidelines assume that the system is not live and that the system is new.

Hot commissioning

Hot commissioning is possible, that is, you can commission the controller(s) as part of a live system. However, in addition the

normal commissioning risks, the live system itself presents challenges and risks that must be anticipated and mitigated.

DANGER!

For a hot commissioning, qualified and experienced personnel must carefully consider the effect of each

commissioning step. Mistakes may cause death, personal injury, and/or damage to equipment.

Retrofits

Retrofits are possible, that is, you can use the controllers to replace the controllers in an existing system. This may involve

commissioning just one controller at a time, and/or hot commissioning. However, in addition the normal commissioning risks,

the existing system, and, in the case of hot commissioning, the live system, present challenges and risks that must be

anticipated and mitigated.

DANGER!

For retrofits, qualified and experienced personnel must carefully consider the effect of each commissioning

step. Mistakes may cause death, personal injury, and/or damage to equipment.

DANGER!

For hot commissioning and retrofits, good communication is essential. Respect all limitations from the

system owner or operator. Always check before touching or changing any existing wiring.

INFO

During a retrofit, you can use switchboard control and the switchboard GOV up, GOV down, AVR up and AVR down

controls to transfer the load to the first new controller as it is commissioned. Once two or more new controllers are

commissioned, you can use the load sharing parameters to transfer the load to the new controllers.

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