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The Microgrid Perspective Unleashing renewable fuels now to bridge the gap to net zero Diesel generators are often attractive in regard to power density and cost, but can fall short for companies with sustainability commitments such as achieving net-zero emissions. All shutdown faults, including those overridden by Battle Short, must be acted upon immediately to ensure the safety and well being of the operator and the genset.
This feature should only be used during supervised, temporary operation of the genset. The faults that are overridden during Battle Short mode consist of faults that can affect genset performance or cause permanent engine, alternator, or connected equipment damage.
Operation may void generator set warranty if damage occurs that relates to fault condition. When Battle Short mode is enabled, the Warning status indicator is lit, along with displayed fault code — Battle Short Active. With Battle Short mode enabled and an overridden shutdown fault occurs, the shutdown fault is announced but the genset does not shut down, and fault code — Fail To Shut Down is displayed.
Moving the customer installed Battle Short switch to OFF with an active but overridden shutdown fault or a shutdown fault that was overridden at any time will cause Fault code — Shutdown After Battle Short to become active.
The software for the Battle Short feature must be installed at the factory or ordered and installed by an authorized service representative. When installed, the InPower service tool is required to enable the Battle Short mode feature and to configure a Customer Input for an external switch input.
There will be different calibrations for various engine families. In order to do this a save trims command must be sent to the controller.
Upon receiving the save trims command; the PCC waits for zero engine speed and then writes all of the internal parameters in volatile memory to nonvolatile memory. Before initiating a start sequence the genset control refreshes all of the parameters in its memory, thusly any unsaved changes to trim parameters will be lost following a start command.
A save trims command should only be sent to the controller after a parameter change. This list is not inclusive of every parameter that needs configuration, these are just the biggest ones. All the overload protection thresholds correspond to set KVA rating.
Nominal Voltage — The nominal voltage should be set as per the voltage rating of alternator. Setting up a different nominal voltage other than the referred on alternator nameplate may cause damage to alternator. This parameter is required to be set within 3 phase high connection genset nominal voltage hi limit and low limit or 3 phase low connection genset nominal voltage hi limit and low limit. Failing to do so, will cause an error in metered load Amp, KVA, KW sensed by controller causing mal-functioning of alternator protection.
Number of Hertz Alternator Line Frequency may be over nominal frequency before Overfrequency fault becomes active. Minimum time the keyswitch driver command needs to be on before CAN datalink health will be checked. List of feature installed at the factory. List of feature installed in the field. Trim to define the 20 character string for use by the Operator panel when this fault becomes active. Sets the maximum amount of time to engage the starter during a single crank attempt when using the cycle cranking method.
A method of adding in a frequency offset to the base frequency subject to high and low limit calibrations. The frequency amount which the load dump underfrequency threshold is below the final frequency reference. A trim that sets the delay time for generating the inactive and active fault reports to the event handler. Sets the maximum number of times to engage the starter when attempting to start engine using the cycle cranking method.
When set to Reset Commands will reset the modbus control logicals to an inactive state when Modbus communications are lost. Time delay before the control activates the modbus failure fault after the master is sensed as no longer present.
A trim that sets the delay time for the keyswitch when initialy shutting down on datalink failure. If enabled synchronizer will turn off on a fail to sync.
Sets the fail to synchronize diagnostic time delay. Sets integral gain for the frequency match PI loop. Sets overall gain for the frequency matching control. Sets the speed control method for isolated bus paralleling. Sets the voltage control method for isolated bus paralleling. Sets overall gain for the phase matching control. Sets the synchronizer slip frequency. Sets overall gain for the voltage matching control. Overall kVAR load share gain adjustment. Use to adjust kW sharing balance between gensets.
Overall kW load share gain adjustment. Sets the speed droop percent from no load to full load. Sets the voltage droop percent from no load to full load 0. Sets the genset load govern kW base load. Sets the load govern setpoint for genset. Sets the integral gain for kVAR load governing control. Sets the proportional gain for kVAR load governing control. Sets the nominal maximum kVAR output. Sets the integral gain for kW load governing control. Sets the proportional gain for kW load governing control.
Sets the nominal maximum kW output as. Use to select whether kW load govern. Sets the utility kVAR peak shave internal. Sets the utility kW minimum load level for.
Sets the utility kW peak shave internal operating setpoint in units of kW. Sets the utility kW peak shave internal. Sets the maximum frequency difference allowed for permissive close.
Sets the center frequency for the genset frequency sensor bandwidth settings. Sets drop-out delta for genset frequency sensor as percent of center frequency. Sets drop-out time delay for genset frequency sensor. Sets pick-up range of genset frequency sensor as percent of center frequency.
Use to enable genset frequency sensor. Sets the time delay from when one source. Sets the amount of time that the utility.
Defines system phase rotation for use with rotation sensors. Use to choose whether a test is with load or without load. Sets the amount of time that the genset. Sets the center frequency for the utility frequency sensor bandwidth settings.
Sets drop-out delta for utility frequency sensor as percent of center frequency. Sets drop-out time delay for utility frequency sensor. Sets pick-up range of utility frequency sensor as percent of center frequency.
Use to enable utility frequency sensor. Sets drop-out time delay for utility overvoltage sensor. Sets drop-out as percent of nominal voltage for utility overvoltage sensor.
While applying an HMECM control to a new application, these parameters should be ensured to have appropriate values. Model Specific features like nominal voltage, frequency, Engine protection values Governor Gains, etc have to be assigned appropriate values at manufacturing time via Feature Codes.
Creating New Feature codes for a new application shall be a responsibility of the corresponding application engineering team.
The default values of the parameters have been reviewed. Sets overall AVR gain in 50Hz applications. This is a true proportional gain which is multiplied against the voltage error signal. Controls the recovery shape of voltage transients in 50Hz applications. This is a true integral gain which is multiplied against the sum of all previous errors. Affects high frequency characteristics of the AVR algorithm in 50Hz applications. Adjust for voltage stability reasons.
Sets overall AVR gain in 60Hz applications. Controls the recovery shape of voltage transients in 60Hz applications. Affects high frequency characteristics of the AVR algorithm in 60Hz applications. Work instruction ET describes the procedure for tuning a genset equipped with the PCC control. The remainder of this genset tuning section should not be necessary if the document above is correct and complete.
Standard values for the K1-K4 and Damping terms for both 60 and 50Hz for Newage range alternators are listed below. Insert ET — This document covers how to tune a genset.
The values of K3, K4 and the Damping factor are set for basic stability reasons and should not need to be adjusted, but can be adjusted if necessary. The value of K1 should be adjusted to meet the specification for percent off rated voltage during a load acceptance, and prevent large voltage overshoots during offloads. The value of K2 should be adjusted to control the recovery characteristics of the voltage during large load acceptance and rejection transients.
Values of K2 which are too high can cause unstable voltage performance and values too low can cause slow performance or steady state voltage offset errors. In general, K1 increases and K2 decreases in value with increasing generator size, but can vary in different applications.
If an initial value of PCC gain does not fall within the given criteria, use the closest equivalent and tune the PCC for proper performance.
Due to the non-linear relationship in the lower two PCC zeroes at these lower K2 gain levels, the accuracy of this conversion is not as good as the one for the higher K2 gain values. But, the reverse is not true. The voltage set point command is calculated from the frequency error between commanded frequency and the actual frequency.
For example, a voltage set point of There is no offset to voltage for errors above nominal frequency. GK1 Idle. Affects high frequency characteristics of the governor algorithm. Adjust for Idle mode speed stability reasons. It slows the overall response of governor during Idle operation.
Tuning Governor Rated The following gain characteristics allow tuning of the governor when genset is running in Rated. GK1 50Hz. Sets overall governor gain in 50Hz applications. This is a true proportional gain which is multiplied against the frequency error signal. Controls the recovery shape of speed transients in 50Hz applications.
This is used in 50Hz application. Sets overall governor gain in 60Hz applications. This is a true proportional gain which is multiplied against the speed error signal. Controls the recovery shape of frequency transients in 60Hz applications.
Affects high frequency characteristics of the governor algorithm in 60Hz applications. Adjust for frequency stability reasons. This is used in 60Hz application. This parameter shall be adjusted to minimize the hunting due to Genset to Genset variations. This parameter is very important to HM systems in the cold start scenario. If the genset is going to start in cold conditions, this parameter needs to be set as high as possible to ensure that the engine is as warm as possible when the governor is enabled and the engine can respond to the fueling commands to increase speed in a timely manner helps prevent over fueling.
This parameter is used in conjunction with the governor preloads and the ramp times to help prevent over fueling. If the genset will not ever be started in the cold, this trim can be set anywhere within its adjustment range with little if any consequence to performance. Notes: A good starting point for any new engine application is to start with a set of released gains for an engine of a similar type and size should they already exist.
If a set of pre-developed gains are not available, the gains listed above should work well enough to start most engines and to allow them to run smoothly. The value of GK2 should be adjusted to control the recovery characteristics of the engine during large load acceptance and rejection transients. GK2 is a true integral type gain and is applied to the governor output as GK2 times the sum of all the previous governor error. Values of GK2 which are too high can cause unstable voltage performance and values too low can cause slow performance or steady state voltage offset errors.
The values of GK3, GK4 and the Damping factor are used to set the basic steady state stability of the engine, but also influence the overall speed of response of the governor in transient situations. Adjustment of GK3 and the Damping factor is an iterative process started by finding the engine load level which produces the worst steady state engine performance note: GK1 and GK2 may have to be adjusted first to allow the engine to be transitioned smoothly into this and adjusting GK3 until the best performance is observed, then doing the same for the Damping factor.
Repeat this process at least once to ensure that the best possible values for GK3 and the Damping term have been determined. Most engines have some load level which is inherently less stable than others and must be found to determine the correct value for GK3 and the Damping term. Note: It is important to control the steady state performance of the engine. Unstable engine performance will be carried over into the generator. Very fast increases or decreases in engine speed, even if the magnitude of the increase or decrease is small, will tend be carried into the alternator voltage as large increases and decreases in voltage at the same frequency as the engine speed changes.
Do a series of load steps to determine the transient characteristics of the genset. In general, these values should be adjusted to achieve the maximum possible performance from both the engine and the alternator. A production test spec if available should give the full load step transient performance levels for any given genset model.
This is a very iterative process and many require some time to find the best combination of gains to fit the application. In general, adjust GK1 to control the peak frequency during transients and adjust GK2 to control the recovery shape of the frequency transient. Re-verify steady state voltage and governor performance. Follow the same process as used at 60Hz. The order of 50Hz vs 60Hz testing can be reversed. When this feature is enabled GK1 gain value is changed dynamically based on the speed error value.
This helps to improve the transient response of the genset. If the values are not tuned properly one may observe oscillation after transient load conditions. Governor Speed Delta High — This trim sets the governor speed error high limit.
The purpose of this trim is to allow the gain switching when the engine speed is greater than reference speed plus Governor Speed Delta High value.
This parameter is covered under governor control setup Governor Speed Delta Low — This trim sets the governor speed error low limit. The purpose of this trim is to allow the gain switching when the engine speed is less than reference speed minus Governor Speed Delta Low value. This parameter is covered under governor control setup. Determine correct values for the startup fueling parameters. The controls default values should work well. Cold weather applications might need a longer cranking period and OR higher levels of cranking fuel.
Following parameters should be chosen to make sure the genset starts up quickly enough but does not overshoot or produces excessive smoke at startup. Initial Fueling. Value too large will cause excess fueling which will effect in smoke at startup, possible over-speed or Crank exit value to large.
Start with a low value and go on increasing till smooth start is observed. Value too large will cause increase in starting time and increased use of starter and batteries. Value too small will cause excess fueling which will effect in smoke at startup, possible over-speed or Crank exit value to large. Value too low will cause speed overshoot.
Value too high will cause increase in starting time. After this period expires, the fuel command will be ramped at the Crank Fueling Ramp Rate until the Maximum Crank Fueling limit is reached.
When the Governor Enable Engine Speed is reached the governor is enabled, the speed setpoint is set to the sensed engine speed value at this point, and the setpoint is ramped to rated speed in a time equal to the Governor Ramp Time. The diagram below illustrates these set points. Non-Linear Actuator Compensation It is actively used in gaseous fuel applications that use a butterfly valve for fuel actuator that has nonlinear fuel flow characteristics over its full range of throttle positions.
This helps in tuning the Governor of. Gaseous fueled engines. Gov Duty Cycle compensation feature. Governing General Minimum Duty Cycle — This parameter sets the minimum limit for governor duty cycle. When the error is maximum on positive side and the PID tries to control the speed this is the value which will be driving the actuator. One has to tune the minimum value such as the PID works properly. Maximum Duty Cycle — This parameter set the maximum limit for governor duty cycle.
This trims primary purpose is to protect the power electronics in the control. We have a typical rating of 4A continuous, 6A peak on our governor drives, the Max Duty Cycle needs to be set to protect those limits if the max possible actuator current can exceed this.
If the actuator current cannot exceed this a many do not , then just set the limit high,. Do not set it too high as this will cause hammering of the actuator at the full open position.
This will cause excessive wear of the actuator. The high value also may cause instability in the control system. One can gradually increase the Override value to determine the Maximum Duty Cycle at which the Actuator is either full open or full close depending on the type.
This parameter shall be adjusted after gain tuning to smooth out the starting operating. If the value too small the Speed will drop after crank and if the value is too high the speed will surge. Dither Factor — Dither is a method of introducing small amount of noise into the speed governing system.
The purpose of this feature is to prevent the fuel actuators from becoming stuck. Therefore dither should be used in applications where the fuel actuators are prone to sticking. The exact value is a function of the application.
There is a performance trade off when using this. One will typically gets worse steady state performance while using this, but if the actuator is sticking when a transient event occurs, and there is no dithering, the freq deviations could potentially be very high, out of spec or causing an over speed event.
Do not use dithering if the governor output is being used as a set point source for some other smart device or actuator, which is driving the actuator itself. Alternator Startup The alternator will be started up and brought to rated voltage when the engine speed reaches rated speed. The regulator will now bring the voltage up to rated voltage. Simulated operator panel user interface for PowerCommand genset and transfer switch controls.
Tabular view of data for Cummins network components. Supports concurrent monitoring of one local or one remote network connection; or can directly monitor controls via a direct serial interface. Strip chart and monitor functions allow real-time data gathering and display of user defined points. Compare utility allows comparison of site data. Allows multiple monitoring windows to be open. Alarm pop-up window provides notification of alarm conditions. Alarm logging for historical record keeping.
Standard reports and data exporting capabilities to allow user development of custom reports. WinBEEP 32 interface for alarm notification via a pager system. Sends email on alarm conditions. All rights reserved Specifications subject to change without notice Cummins Power Generation and Cummins are registered trademarks of Cummins Inc.
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