The document describes an automatic synchronization and load sharing system between two diesel generator sets. When the mains power fails, the master generator set is started and picks up the load once its voltage is healthy. If the load reaches 80% of the first generator's capacity, the second generator is automatically started. Load is then shared between the two generators proportionally to their capacities. The generators continue to run in synchronization until the load drops below 80% of one generator's capacity.

1. AUTO SYNCHRONIZING AND AUTO LOAD SHARING 02/10/12

2. SINGLE LINE DIAGRAM 02/10/12

3. When mains are healthy, both the DG’s remain in the standby mode. When mains fail , Line Voltage Monitor (L.V.M.) senses. Starting pulses are given to the Master D.G. Set. (Master D.G.Set is automatically selected by programmer.) After satisfactory starting of the D.G.Set 1, voltage is sensed by Generator Voltage Monitor (G.V.M.). If voltage is healthy, then closing signal is given to D.G.1 breaker and it is closed. Synchronizing Panel gives corresponding pulses to start load automatically. The load is then sensed by KW transducer in the panel & continuously monitored by PLC. 02/10/12

4. Engine & Alternator parameters are also continuously monitored by P.L.C. in the Panel. In case of any fault (e.g. Low Lube Oil Pressure, High Cooling Water Temperature etc.), breaker is tripped & engine is stopped. If the load reaches & crosses 80 % of the rated capacity of the D.G. 1, then starting pulses are given to the second D.G.set by P.L.C. When D.G.2 starts, then again G.V.M. checks the voltage, and if voltage is healthy, then breaker 2 is closed. After closing of the second breaker, Auto load sharing function starts sharing the load between the two D.G.Sets. The percentage of sharing is directly proportional to their individual capacities. Since sharing is proportional to their respective capacities, even D.G.sets of different capacities can be synchronized successfully. 02/10/12

5. D.G.sets continue to run in Synchronization until the load is above 80 % of any one D.G. set. When load comes below 80 % of any one D.G. set, then the automatic signal is given to that D.G. & then it starts taking the full load. After transferring the total load to one D.G. (on which 80 % load is to be connected), the breaker of the second D.G.is opened. Now one D.G.is taking the load The second D.G. is then stopped after its cooling period. When mains are resumed, then load is transferred to the mains & both the D.G.sets are stopped after their cooling period. 02/10/12

6. The total Automatic operation has a manual override. In manual mode, the total operation can be performed manually. Auto load shedding facility can be incorporated by suitable programming of PLC. With this facility, various loads can be brought in or switched off at particular time or for various intervals. 02/10/12

7. ADVANTAGES OF AUTO SYNCHRONISING & AUTOLOAD SHARING Changing of logic is very easy because of changes are made through software only. There is no changing of wires, adding of components like relays, contactors, which is very time consuming, cumbersome & requiring additional space. For any type of load addition or reduction, manual intervention as regards D.G.set operation is not required. However, in case of emergency manual override is possible. Because of KW dependent load sharing, optimum utilization of D.G. sets are possible. This increases D.G. sets efficiency & saves lot of fuel. Use of PLC reduces no. of relays, contactors, wiring etc. This reduces fault points & increases the MTBF of the system. All the future changes / modifications can be easily made through software only. 02/10/12

8. Automatic Changeover 02/10/12

9. Mains source failure Automatic Changeover Switch panel is designed to monitor & to start Generator control panel automatically when the mains source fails partially or fully. The control panel provides a potential-free contact output & provides signal to the remote generator control panel to enable automatic start of the generator. On sensing that the generator is running at correct output the changeover switch changes over from the mains position to generator position, thereby transferring the site load. 02/10/12

10. When Mains restores L.V.M. checks the mains for its healthiness, the generator is then disconnected from the load and automatic changeover back to the mains source takes place. Load is now connected to the mains. Gen set is then run for about 5 minutes time set, on no load and it is stopped automatically. 02/10/12

11. AMF Panel 02/10/12

12. AMF Control panel is designed to monitor & to start Generator automatically when the mains source fails partially or fully. When mains fail, then it is sensed by Line Voltage Monitor (L.V.M.) and three starting pulses are given to Gen set. If Genset does not start within three attempts, then ‘STARTING FAILURE’ alarm is sounded and stop signal is given to Genset to stop it fully & no start signals are given further. When Genset starts successfully, it builds up the rated voltage and Genset contactor/breaker is closed automatically. The load then is switched on / transferred to the Genset. When Mains restores, which is checked by L.V.M. for its healthiness, the generator is then disconnected from the load and automatic transfer back to the mains source takes place. Load is now connected to the mains. 02/10/12

13. Genset is then run for about 5 minutes time set, on no load and it is stopped automatically. Safeties like L.L.O.P., H.W.T. and over speed are operative when the Genset is running. For any of the above faults, Genset stops immediately. Automatic function can be totally by-passed and Genset can be started-stopped in manual mode also. 02/10/12

14. Indication for the following :Low oil press High room temp. Over speed Fail to start DC battery REV POLARITY Engine hours run counter RPM Frequency Voltage Current Engine temperature 02/10/12

15. Shutdown Protections Low oil press High room temp Over speed Fail to start Under speed Over current V belt failure Blower failure Earth fault 02/10/12

16. PANEL ACCESSORIES 1 Voltmeter 3- Ammeter 1- Freq. RPM meter Fail to start 1- Battery voltmeter 1-Engine hours run counter 1- Oil press. Gauge 1- Engine temp. gauge 3- C.T. above 100 A 02/10/12

17. 1- voltmeter sel. Sw 1- Electronic generator control module fully programmable with : Control key switch Off / Run / Start (OPTIONAL) 1- MCB / MCCB 4- AC and DC fuses 1- Control terminals 1- Neutral terminal 1- Set of AV mounts (OPTIONAL) 2- 20/30 amp rated relays for fuel and start solenoids 02/10/12

18. Kw TRANSDUCER 02/10/12

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21. A) VOLTAGE LEADS Connect the leads to the electrical source to be monitored. B) FUSE C) 4-20mA OUTPUT CONNECTOR D) STATUS LED The LED blinks green when the product is functioning normally. It will blink slowly, approximately one second on, then one second off. If the LED is red and blinking slowly, it may indicate incorrect wiring or a power factor that is less than 0.5. If the LED is red and blinking fast the CT's maximum current rating has been exceeded. E) EXTERNAL CTs 02/10/12

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23. OPERATION Kw TRANSDUCER combines a microprocessor based kW transducer and high accuracy split-core current transformers (CTs) in a single unit. Split-core design eliminates the need to remove conductors. Three CT versions is used with three phase, unbalanced loads. 02/10/12

24. Applications  Optimization of chillers, pumps and cooling towers  Energy management & performance contracting  Process control  Real time power monitoring 02/10/12